Manufacturing Today Europe Issue 122 November 2015

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BEST PRACTICES FOR INDUSTRY LEADERS

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The lone

danger Firms must recognise the need to take serious steps to protect employees working in isolation

Also in this issue:

Automobile manufacturing Workforce wellbeing Workforce management

Case study-Messier-Bugatti-Dowty Future of manufacturing IT in manufacturing

EUROPE

122 November

MANUFACTURING

Editor’s Comment

Editor Libbie Hammond Art Editor/Design David Howard Studio Assistant Barnaby Schofield Staff Writers Jo Cooper Andrew Dann Ben Clark Production Manager Fleur Daniels Production studio@schofieldpublishing.co.uk Advertising Administrator Tracy Chynoweth studio@schofieldpublishing.co.uk

Business Development Director David Garner Operations Director Philip Monument Editorial Researchers Laura Thompson Jeff Goldenberg Mark Cowles Tarj D’Silva

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ith recent CBI figures indicating a decrease in UK manufacturing output, and the strengthening pound further impacting exports; we approach Christmas in tough conditions.

However, the messages I am seeing still remain positive. Tom Bouchier, managing

director, FANUC UK asserts that manufacturers shouldn’t panic as going forward there will be enablers of future growth to stabilise overall conditions over the next quarter. The UK government’s upcoming Comprehensive Spending Review has also been flagged by several commentators as a pivotal opportunity to announce strong investment in innovation and skills as these are vital to boosting performance in exports, enhance manufacturing growth and improve productivity.

Firms have signalled that they expect that the situation will stabilise over the next quarter – what do you think?

libbie@schofieldpublishing.co.uk

MANUFACTURING

Autumn 2015

Advertising Sales Joe Woolsgrove - Sales Director Tim Eakins Dave King Darren Jolliffe Mark Cawston Emma Kerton Andy Ellis

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BEST PRACTICES FOR INDUSTRY LEADERS

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EUROPE

Chairman Andrew Schofield

Follow us at: @MTE_magazine

The lone

danger Firms must recognise the need to take serious steps to protect employees working in isolation

Schofield Publishing

Cringleford Business Centre, 10 Intwood Road, Cringleford, Norwich, NR4 6AU, U.K. Tel: 044 (0)1603 274130 Fax: 044 (0)1603 274131 www.manufacturing-today-europe.com

Also in this issue:

Automobile manufacturing Workforce wellbeing Workforce management

Case study-Messier-Bugatti-Dowty Future of manufacturing IT in manufacturing

©2015 Schofield Publishing Ltd Please note: The opinions expressed by contributors and adver tisers within this publication do not necessarily coincide with those of the editor and publisher. Every reasonable effor t is made to ensure that the information published is accurate, 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 proper ty of Schofield Publishing, and may not be copied, stored in a retrieval system, or reproduced without the prior written permission of the publisher.

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Features

6 Time to buckle up 4 News

14 From idea to reality

Updates and announcements from the manufacturing arena

A sophisticated IT solution designed to streamline processes and increase efficiency has been implemented at a landing and braking systems manufacturer

6 Time to buckle up The industrial use of 3D printing is one of the new game-changers in the automotive manufacturing sector

14 From idea to reality

16 The future of manufacturing Manufacturers should be considering how to adapt and embrace the new trends that are appearing now

18 Modern manufacturing challenges Best-in-class manufacturers are leveraging new product cost management tools that equip employees to remove costs at every opportunity

9 The voice Happy and motivated workers produce better results, and voice-directed work in the warehouse can help

20 The lone danger

12 An integral role

UK businesses need to face up to the reality that lone workers face dangers and they are responsible for their safety

Jo Cooper discusses the benefits of using workforce management software in the manufacturing sector14 From idea

22 Need to know Proposed changes to health and safety guidelines have implications for the manufacturing sector

20 The lone danger

12 An integral role

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CONTENTS

Profiles

24 Stadco

24 Stadco 40 Sulzer Pump Solutions Ireland 46 Collini 51 Laufenberg 54 Kel-Tech Engineering 57 Skamol 60 Sharpak - Yate and Bridgewater 66 Kannegiesser UK 69 Waldrich Coburg 72 Rexnord FlatTop 40 Sulzer Pump Solutions Ireland

75 Salop Design and Engineering 78 Hi-Force 81 Chemigraphic 88 Johnston Sweepers 94 Arjowiggins Creative Papers 97 Nowy Styl Group 101 SGB-Smit

104 Apple International 107 ATAG Verwarming

Nederland 111 Tomburn 114 TOMRA Sorting Solutions 119 DesleeClama 121 TS Tech UK 125 Gooch & Housego 128 Airius Europe 130 Valtra 132 Frigoglass 134 Ferrum 136 Lovink Technocast 138 Zollern 140 Tandom Metallurgical

Group 142 Burgess Furniture 144 Ekamant 146 Hitzinger 148 Step-Tech 150 Summitglow 152 Br端sch Precision 154 friedola TECH 157 SML Maschinengesellschaft

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European growth continues Tata Technologies has announced plans to move into a new office in Brasov, Romania. The new office will grow Tata Technologies’ operations in Romania by over 50 per cent. The structure of the building has been finished and the exterior is expected to be completed by November.

It is anticipated that the company will move offices in April 2016.

Commenting on the expansion, Gabriel Radulescu, General Manager of Tata Technologies’ Romanian operations, said: “This office clearly shows Tata Technologies’ commitment to supporting growth of operations in Romania. It will provide our employees with a modern and inspiring work environment and allow us to attract the new talent required to grow our business.

“The Coresi Buisness Park will provide us with the sort of infrastructure we need as a company and is located within the city centre, which will allow employees to reach us easily.

The location will also offer more visibility to the Tata Technologies’ brand in the local area.”

The new office in Romania will accommodate Tata Technologies’ growth targets and forecasts over the next three to five years in the market, where the company has been operating for the past 10 years. The new office will house Tata Technologies’ engineering support services that will further develop the company’s capabilities and growth opportunities, especially in the industrial machinery and automotive sectors.

Centre for excellence Plans have been unveiled for UK’s first multimodal logistics training centre, called Modal Training Limited. The new £7 million centre of excellence for the ports, energy and logistics sectors is being jointly funded by the Grimsby Institute and the Humber LEP. It will be located in a 5,696 m2 fit for purpose designed facility on Kings Road in Immingham, in the former construction facilities owned by Fabricom ENGIE. Equipped with state-of-the-art simulators for training maritime crew, truck and crane drivers, Modal Training will deliver realistic training, replicating the working environment, in a wide range of settings. Facilities will include extensive warehousing, engineering and rail safety teaching facilities, and the UK’s only Air Freight Forwarding Academy.

Mike Parker, Chair of the Humber LEP’s Employment and Skills Group, said: “It is fantastic that we are marking another first for the Humber – the UK’s first single point of study for a diverse range of qualifications suited to all modes of transport. Logistics are vital to supporting the Humber’s growing renewables sector, as a source of new career opportunities and in consolidating our status as the UK’s Energy Estuary.

“To enable current and future work forces to take maximum advantage of the new jobs which are being created, we must meet the challenge of bridging the skills gap. This is why the LEP supported GIFHE’s case for a major investment in the Logistics Centre and worked with Government to ensure Local Growth Funding was allocated.”

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New international partnership Leading filter manufacturer, Croft Filters, has teamed up with Czech Republic-based metal experts, Technotron-Metal, to bring a new realm of innovation to the UK. The partnership will allow Croft to utilise Technotron’s range of expanded metals to offer its customers cost-effective, high quality solutions, while also significantly reducing the amount of material used when creating bespoke products to suit exact applications.

Neil Burns, director of Croft Filters, said: “Joining forces with Technotron-Metal has enabled us to offer businesses a wider range of products and services, while also addressing the European-wide demand for expanded metal products. By sharing our in-house expertise, both companies can provide a comprehensive service to customers and source new solutions to meet complex design requirements.

“As well as demonstrating Croft’s commitment to understanding our customers’ needs, this partnership highlights the importance of investment in our team’s knowledge of filters and the future of the industry.”

Croft worked with the CzechTrade Agency to facilitate the partnership with the leading manufacturer of expanding metal, and has since been confirmed as the sole UK distributor of its products, which include perforated sheets and steel gratings.

Croft’s collaboration with Technotron will further bolster its in-house services, in addition to its portfolio of expert partners, which includes HecoFilters.

Tomas Mischinger, managing director of TechnotronMetal, added: “There is a huge potential for expanded metal products in the European market so we’re looking forward to working with Croft and making the most of the team’s expertise and in-depth experience in the industry.”

Wrap up this winter As winter approaches, people who spend time working outdoors should be prepared to face freezing temperatures, heavy rain and strong winds. Being exposed to such weather conditions can become a threat to people’s health, both mentally and physically. Following Arco’s introduction to the benefits of a weatherwear layering system, the company has developed an online Weatherwear Selection Tool to help workers select garments that will keep them warm, dry and comfortable in extreme weather conditions. The tool has been designed to assist customers with choosing the most appropriate layers by guiding them through the selection process and then presenting them with their chosen base, mid and outer layer combinations.

The layering system is the perfect way to ensure weatherwear is suitable for the cold. The breathable base layer sits next to the skin and keeps the body warm and dry. The mid layer, known as the ‘insulating layer’ should be made from synthetic or acrylic fabric. This layer should be fitted to allow minimum air movement, which ensures that maximum heat is retained. The outer layer is the shield against wind, rain and abrasion.

In addition to the Selection Tool, Arco has developed an Expert Guide to Winter Weatherwear to provide guidance on identifying and choosing the most appropriate top to toe gear. It offers advice on the concept of cold stress and the possibility of cold induced illnesses and injuries if the correct clothing and protection isn’t worn.

MANUFACTURING NEWS

Report highlights failings

A hard-hitting new report has highlighted critical maintenance failings that risk the long-term health and productivity of British manufacturing. The report, ‘What You Don’t Repair You Destroy’, catalogues a series of problems affecting manufacturing maintenance practices that threaten productivity, efficiency and competiveness.

Published in conjunction with the Institute of Engineering & Technology (IET), the report surveyed 300 engineers in a variety of roles from manufacturing director through to maintenance engineer. Key findings include 71 per cent of engineers describing their maintenance practices as reactive or planned; 50 per cent stating that maintenance training budgets have stagnated or decreased in recent years and that the majority of maintenance engineers receive only five days training or less every year.

Alastair Johnstone, Managing Director of Bosch Rexroth UK, said: “We have been concerned for some time that maintenance practices and skills have not kept pace with advances in machine complexity.

“This report suggests that UK manufacturing is walking a tightrope, with dated maintenance practices and budgetary constraints posing a critical risk to the long-term health of our manufacturing base.

More strategic maintenance, such as condition monitoring and preventive maintenance techniques, are the exception rather than the rule.”

Multi-million pound facility Voith Industrial Services is to open the UK’s most technically advanced wheels and tyres assembly plant in Coventry next year. The new multi-million pounds facility in Torrington Avenue is being developed to meet the growing demand from premium and luxury car brands, such as Jaguar and Land Rover, as well as from other automotive manufacturers including Vauxhall.

The state-of-the-art plant will replace the existing factory - only a few hundred yards away in Torrington Avenue - where wheel and tyre assembly has been carried out for more than 30 years.

The current operation, employing about 80 people, takes place in three buildings covering an area of 97,000 sq.ft. It houses three production lines currently assembling 4000 units a day. The brand new plant will be housed in one building covering 140,000 sq. ft. and will employ more people. A wheel and tyre assembly will be completed in only 12 seconds – compared to 20 seconds on the current line.

Phillip Spencer, Voith Industrial Services’ sales and business development director, said: “More automotive manufacturers recognise our technical expertise and quality … we expect to see our turnover increase significantly over the coming years as our customer base expands.

“The increasing demand for our expertise in wheels and tyre assembly means that we can now invest in the latest automation and computerbased technologies for this operation. This is just one area of our business that has made us a leading supplier to the UK automotive industry.”

Sequencing operations have already been transferred to the new facility, with a new state-of-the-art assembly line being installed in early 2016 and further milestones planned for completion throughout the year

World’s biggest

Siemens is to supply the world’s biggest gearless conveyor drive system to the Cuajone Mine in Peru, which is operated by the Mexican mining company Southern Copper Corporation (SCC).

The modernisation project will entail the installation of a new gyratory crushing and conveyor system by 2016.

In mid-2014, Siemens was chosen by ThyssenKrupp to supply the electrical package to the Cuajone Mine in Peru with a contract valued in the double-digit million euro range. Previously, the ore was transported out of the mine for further processing using a train over a distance of more than six kilometres to the processing plant.The existing railway is now being replaced by an efficient conveyor belt system and a gyratory crusher, for which Siemens is providing the automation system, the power distribution equipment, and the drive system.

Alongside conventional drives, Siemens is deploying primarily Integrated Drive Systems (IDS) with gearless drives which offer a high level of availability by dispensing with many of the wear-prone components such as gearboxes, couplings and motor bearings.

Gearless drives also enable the use of a continuous conveyor belt, eliminating the need for transfer stations and so reducing susceptibility to faults, cutting out the need for high-intensity maintenance and driving down costs.The conveyor belt system comprises three individual sections which are equipped by a total of five Integrated Drive Systems. For the largest of the belt sections, Siemens is supplying two gearless drive systems with an output of 6,000 kilowatts each, comprising a low speed synchronous motor and a Sinamics SL150 cycloconverter.

The two smaller feed and discharge belts will be driven by two 500 kilowatt lowvoltage motors using Sinamics S150 inverters with regenerative feedback capability and one 1200 kilowatt medium-voltage motor.

The converters and motors as well as the gearboxes and couplings for these drives are all supplied by Siemens.The automation components as well as the drive and power distribution technology are provided in modular electrical rooms (E-houses).

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Time to

buckle up L

ittle-known fact: Ransom Olds (as in Oldsmobile) actually patented the assembly-line concept and delivered the first mass-manufactured automobile. But when Henry Ford and his team revolutionised the assembly line with the addition of a conveyer belt a little over ten years later, an affordable car was suddenly within reach of most Americans for the first time.

There was a necessary downside to offer this product accessibility, though. Ford’s new approach to mass manufacturing and its cost efficiencies left room for only a one-size-fits-all approach.

The Model T was for everyone, but Ford Motor Company made all the design decisions right down to the colour. Black, black, or…black?

Fast-forward 100 years and enter a company called Local Motors. It just unveiled a 3D-printed electric car - the Strati - for which people from all over the world submitted

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their design ideas. With 40,000 users strong and a massive number of new ideas crowdsourced daily, the company has taken an unheralded open approach to vehicle design and manufacturing.

This is just the beginning for the future of the automotive industry.

These kinds of changes are impacting industries across the board. The relationships between product designers, manufacturers, and consumers are becoming incredibly intertwined. Views

What’s driving the future of the automotive industry?

Andrew Anagost explains why Model Ts and 3D-printed cars hold the keys on intellectual property (IP) and innovation are evolving, as well. There will soon be the emergence of a ‘supercomputer for everyone’ (more on that in a minute). And the way things are manufactured - like Local Motors’ use of 3D printers and microfactories - is defining an entire landscape shift. Industries - especially automotive are shifting into whole new gears.

The walls of IP are tumbling down. Patents and IP will remain important components to society.

Automobile manufacturing But the growth of the open-source movement shows how community-driven development can spur even more innovation. Walled corporate gardens of research and development are beginning to wither.

Last summer, Elon Musk announced that all patents for Tesla technology would be freely available to use and, hopefully, spur even more electric vehicle (EV) innovation.

“Given that annual new vehicle production is approaching 100 million per year and the global fleet is approximately two billion cars, it is impossible for Tesla to build electric cars fast enough to address the carbon crisis,” Musk wrote in his blog announcement of the news. “By the same token, it means the market is enormous.

Our true competition is not the small trickle of non-Tesla electric cars being produced, but rather the enormous flood of gasoline cars pouring out of the world’s factories every day.” If Musk didn’t take this preemptive strike, the company could actually limit future consumer demand, the overall market opportunity to produce more EVs, and, really, its own growth as competition to the ‘gas guzzlers.’ With that move, the doors have been blown wide open. A modern-day Henry Ford can now take on patent-free EV innovation.

Image courtesy of Magna Steyr Design

A supercomputer for everyone In the near future, any designer or engineer with a good idea will be able to review multiple, alternate versions of their idea (some suggested

by the computer itself), and make the right design decision much earlier than ever before. Will it work or not? Can I manufacture it? Will it last as long as it needs to? No more question marks.

You’ll know the answer to these questions ahead of time.

Wait a minute: How will that work exactly, you ask? Everyone will have a ‘supercomputer,’ even if it’s just your laptop. Seriously. The ultimate supercomputer is not just accessing the cloud. It’s the cloud, plus an entire

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Automobile manufacturing Image courtesy of Technicon Design

galaxy of information, algorithms, and human collaboration.

Take something that’s seemingly simple - but in reality extremely complex - like the interior handle of a luxury car. There’s so much more to it: The aesthetic, the materials, the size, the mechanical componentry, durability factors. Software will soon help describe the idea in 3D without the constraints of how to manufacture it. Both the designer and manufacturer will already know ahead of time that the machine will actually work (or not) to produce the handle. This is huge. The days of retooling - a consistently major headache for both the industrial designer and mechanical engineer - will be gone.

Then it goes to another level: The supercomputer will answer questions you didn’t even know to ask. It all comes down to insanely smart algorithms. What if the computer suggested, ‘Why don’t you try this new shape for the handle to accommodate the average size of a human hand?’ You didn’t ask the question, but the computer provided an incredible solution for you.

Don’t worry, this isn’t going to be a 2001: A Space Odyssey HAL type of reality. Beyond the algorithms, the human element of design

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and manufacturing will actually grow, too. Go ahead and crowdsource talent from wherever you need it. Global collaboration will hit new heights. Anyone can access that product expert in Australia . . . or trade partner in Singapore . . . or manufacturer in Detroit. This will all be thanks to the cloud and an entirely new information galaxy.

Factory in your own backyard Finally, accessibility to manufacturing is also transitioning from the need to produce something thousands of miles away. ‘Microfactories’ with research and production all under one small, local roof and ‘manufacturing-as-a-service’ (manufacturing what you want, when you want it, and where you want it) are taking root. There will soon be a whole ecosystem connected to whatever tool you need to use and allow you to produce a product locally, quickly, and to scale.

Of course, 3D printers garner a lot of headlines.

But it’s deservedly so. Case in point: Local Motors 3D printed a Strati car in around 44 hours on the actual show floor at the 2015 Detroit Auto Show last month.

For a reality check, do I think every car will be 3D-printed in the future? Absolutely not. The

industrial use of 3D printing is the real gamechanger here, and the technology is going to enable new shifts in production - just like Ford innovated on Olds’ assembly line.

The road ahead Bearing all of this in mind - from IP to the supercomputer to the ‘new’ manufacturing - here’s the net-net: What it takes to bring a product to market is never going to be the same. Like history has shown with the evolution of the design and manufacturing of cars, it’s time to buckle up once again. It may be a bumpy ride, but the destination will be pretty incredible.

This article originally appeared on Line Shape Space (http://lineshapespace.com/driving-the-future-of-theautomotive-industry).

Andrew Anagost Andrew Anagost is senior vice president of industry strategy and marketing at Autodesk. Autodesk helps people imagine, design and create a better world.

Everyone - from design professionals, engineers and architects to digital artists, students and hobbyists uses Autodesk software to unlock their creativity and solve important challenges. For more information visit autodesk.com.

Workforce wellbeing

The

voice

Productivity and morale in the warehouse. By Darrel Williams

The concept of talking to a machine may not sound like a great motivator, but voice technology has been found to have positive effects on warehouse workers’ work-life balance and overall wellbeing

I

t’s a well-known fact that happy and motivated workers produce better results, as illustrated in findings from a study by Warwick University. The study, carried out in laboratory conditions, found that happier workers were 12 per cent more productive than their counterparts. It underlines staff morale and wellbeing is not just an HR goal: it’s fundamental to business performance levels.

The logistics sector employs over 1.7 million workers in the UK and must actively manage morale to ensure it attracts and retains the best employees. The warehouse is a key focus here, and traditionally may not be seen as the happiest of working environments. But warehouse managers do now have the tools to keep workers motivated, in both what they are doing and how they are doing it, without even physically being there.

Keeping the workforce motivated The concept of talking to a machine may not sound like a great motivator, but voice technology has been found to have positive effects on warehouse workers’ work-life balance and overall wellbeing.

How? Through providing clear guidance and direction over the course of the shift, and enabling greater efficiency.

Through voice-directed work, warehouse staff use small belt-worn portable devices and headsets, leaving them hands-free and eyes-free, focused on the task at hand. Instructions from the warehouse

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Working with both hands free also makes it easier to lift heavy items safely, and having both eyes free means better awareness of your surroundings, thereby reducing the risk of accidents

management system are delivered through the headset, one simple command at a time. The picker confirms each instruction verbally and the system is updated in real time. As instructions are given on an as-needed basis, pickers can concentrate on single actions without distraction or delay, thereby reducing errors.

Compared to manual processes, which involve checking lists or screens while simultaneously trying to carry out high volumes of goods without making mistakes, a great deal of the stress associated with warehouse picking can also be removed.

The result? Businesses adopting voice have seen an average increase of 20 per cent in worker productivity compared with previous systems. At the same time, accuracy rates have risen up to 99.98 per cent, critical when considering that the cost of returning an incorrect item is up to five times as much as processing a new sale.

Incentivise But how does being more efficient make workers happier? It’s the responsibility of the warehouse manager to ensure that a good job does not go unrewarded. But again, voice can help.

With voice in place, it is possible to introduce

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competition and gamify elements of the working day, offering rewards for completing additional tasks or meeting all targets for a set period. With precise instructions given by the warehouse management system, there can be no suggestion of bias towards workers, levelling the playing field for all.

By viewing workflows in real time and monitoring progress, employers can also adopt a more flexible model, re-directing staff onto particularly busy tasks in order to help teammates, for example. This way, the work is completed quicker, which quite simply means that staff are required to work less overtime and can restore the work-life balance.

This use of incentives, better informed by technology, contributes to the overall wellbeing of the workforce, while creating more fully rounded employees.

Health and safety Health and safety should also be considered as important to overall worker morale. Warehouses can be inhospitable at times but the increasing use of technology is helping to produce safer working environments.

For example in freezer picking, wearing a voice headset means no need for workers to remove gloves to type information into a mobile

Workforce wellbeing

computer, a small yet incredibly strong benefit through the course of a working day.

Working with both hands free also makes it easier to lift heavy items safely, and having both eyes free means better awareness of your surroundings, thereby reducing the risk of accidents.

Cumulatively, all of this has a profound effect.

Workers have been shown to be less tense at the end of the day. Their daily tasks become that much easier to achieve, there is a reduction in their worry of making a mistake, and they know they are working as efficiently as possible, allowing them to leave on time.

Is technology the deal-breaker?

The use of technology can therefore be seen as an enabler for the productive warehouse. With the industry reported to be booming at over £55 billion in the UK alone, it’s clearly in the warehouse manager’s interest to develop the most efficient working models possible. Happier workers will be a by-product of this.

So does technology therefore become a factor in a worker’s decision of which company to work for? The choice between using more traditional methods of picking and voice technology, with the benefits as we have outlined, could become a tipping point to securing the best people.

Securing these skilled workers, rewarding them and retaining them allows warehouse operations to run as smoothly as possible. By having the more attractive workplace environment, companies are more likely to attract and retain the best candidates, ensuring quality results.

Meeting peak demands Having a more skilled and motivated workforce will truly pay dividends when seasonal peaks arise. For retailers this is undoubtedly in the lead up to Christmas, as well as e-commerce bonanzas such as Black Friday. By ensuring better accuracy, and putting people at the heart of the process, voice technology can help tackle these peaks without impacting negatively on workers.

By being able to plan for peaks, voice customers have reported they don’t experience issues or see them as a major concern, citing the fact that they are able to upskill new workers quickly and effectively – and meet demands as normal.

Happy workers: Happy managers?

As the logistics industry continues to expand, working environments will doubtless come under further scrutiny. The use of voice in the warehouse means that companies can ensure the process of picking is being done in the most efficient way, allowing managers to focus on

human elements including employee morale and wellbeing.

But of course, having these efficient processes will have already started to make the positive impact managers are looking for. Through allowing warehouse functions to perform at optimum levels, voice systems are building better working conditions, for both employees and employers. One Honeywell Vocollect solutions customer, commented that after implementing the system, they found that the performance of the better, more experienced and motivated staff increased ten per cent. At the same time they saw the performance of the less experienced and sometimes less motivated staff increase by 20 per cent. As everyone is working to similar levels of productivity it’s made managing the workforce much more predictable and accurate.

Darrel Williams Darrel Williams is regional director, Northern Europe and South Africa, Vocollect by Honeywell.

Honeywell is a leading provider of innovative voice technology solutions enabling nearly one million global mobile workers annually to save companies more than $20 billion. Vocollect solutions integrate with most major WMS, ERP, materials handling systems and supports the industry’s leading mobile computing devices. For more information, visit www.vocollect.co.uk or www.vocollectvoice.com.

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An integral

role

Gregg Gordon, Kronos Inc.’s Senior Director of Big Data Practice, talks to Jo Cooper about the benefits of using workforce management software in the manufacturing industry and the integral role big data can play in business optimisation

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With demand for exceptional efficiency throughout production processes continuing to increase, those in the manufacturing sector are looking to workforce management systems to ensure their business remains competitive

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ith demand for exceptional efficiency throughout production processes continuing to increase, those in the manufacturing sector are looking to workforce management systems to ensure their business remains competitive. As such, many companies are realising the benefits of using workforce management software.

Although many manufacturers have held onto a dated view on managing their employees, workforce management systems are proven to boost productivity, enhance labour planning, track attendance and lateness and thus enable manufacturing firms to benefit from significant savings in cost. One provider of this integral service is Kronos Incorporated, a global organisation that is committed to helping companies across a spectrum of industries to manage their most valuable and expensive asset, the workforce.

“Kronos Incorporated is a privately owned company, with just over $1 billion in revenue; we have customers in more than 100 countries and a little over 4000 employees. The majority of our customers are in the US, with the UK our second largest market. We have also seen strong growth in China and developing countries such as India,” begins Gregg. “Kronos’ primary offering is known as workforce management, which means we help customers to control costs, improve productivity and minimise compliance risk. We work across all industries, including retail, manufacturing, healthcare, distribution and the public sector; to differentiate ourselves, we have sales and support service providers that are focused on one industry each, which means they have a comprehensive understanding of the business they are working with.

“Workforce management can mean punctuality, such as punching in and out, or it can mean attendance.

We can also look into scheduling so a customer can align their workload with the right amount of people, which means employees are not overworked but also means the company isn’t losing money from people waiting for work. We also offer labour tracking on the production floor so we can understand the details of productivity, such as if there was scrap produced, why was this produced? On top of this, we also have analytics that pull information from all of these systems, we then provide insights on that.”

By taking the complexities involved in recording time and attendance transactions, scheduling diverse workforces, managing employee absence and simplifying these areas of operation in the cloud, Kronos Inc. streamlines HR and payroll processes, ensures companies hire the best people and enables managers to make informed, fact-based decisions that will enhance productivity and cost effectiveness.

Playing a key role in workforce management and the streamlining of manufacturing activity is big data, which enables manufacturers to find core parameters that explain yield or productivity variations and

Workforce management Workforce Auditor

By accurately analysing large amounts of data, Kronos Inc. helps manufacturers to find patterns throughout operations and learn the strengths and weaknesses of their employees; this could result in teams being redeployed for jobs more suitable for their skills

rectify these issues accordingly. For example, big data and advanced analytics can enable manufacturers to see the quality, performance and training variances of each machine and operator; highly valuable information that can streamline workflows in a production centre. Ultimately, by accurately analysing large amounts of data, Kronos Inc. helps manufacturers to find patterns throughout operations and learn the strengths and weaknesses of their employees; this could result in teams being redeployed for jobs more suitable for their skills, or replicating an effective operating process used by one team throughout the entire organisation.

Elaborating further on data collection, Gregg states: “Data collection wholly depends on the objective of the customer; so we collect time punches, enter the schedules of production and compare this information to the people who worked that day. Basically, every time you touch the system we collect data on what happened, and the reason for this is because many countries require time and payroll data to be kept on file for several years. This is so companies have highly detailed records should a grievance between an employee arise or a regulatory agency requires a look into practices.

“We also track work orders and the exact

amount of time spent by each person in production, such as how much is produced and what waste was generated. Customers may also want to track a serial number of a part they used, for example, if a military client needs to trace a part if something fails or how many parts were actually used throughout production. In addition, Kronos tracks production data such as when machines are running or go down in production.

If a machine is down, why did it go down?

Data collection devices include clocks, barcode scanners, mobile devices and data entered through web forms. This is the data that is used to calculate regular and premium pay, provide the status of employees and work as well as generate traditional reports.”

He continues: “What big data offers is a method to extract new value from data that has been collected for the previously stated reasons.

This data can be reconciled with external data to provide new perspectives or statistical methods can be applied to larger amounts of data to identify patterns and outliers that are not evident in traditional reports or even by supervisors walking the line.

An example of big data is by applying machine learning to the edits made to timecards and schedules. Each of these edits is a small trade of time and money between the company and an employee. Two resources that are highly valued by both. By looking at millions of these transactions across all employees subtle patterns and outliers can be identified. Most interesting is that it provides a view into how supervisors are acting.

Often only a supervisor can edit an employee’s timecard or schedule. This gives them significant discretion over these resources. By looking at how all supervisors act, we can supervisors exhibiting new best practices, those that are showing favouritism or those that are adjusting timecards to benefit their own performance or pay at the expense of either the company or an individual employee.

“Through big data we can take a large

group of employees and reduce the number down to ten to 15 employees who are acting suspiciously repeatedly. From there we can help identify negative or positive activities within the workforce that can either be rectified or replicated to enhance productivity, morale and cost effectiveness. Our product, Workforce Auditor, will be launched in September as part of our Workforce Analytics application; we are excited about this because so far we have used this analysis on ten customers, all of which have been made aware of situations that needed to be addressed,” says Gregg.

After 20 years of focusing on waste reduction and product quality improvement, the manufacturing industry is steadily developing an increasing interest in the benefits of using big data. Prepared for this burgeoning trend, Kronos’ new Big Data Practice group will continue to provide valuable insight into the pitfalls and opportunities in its customers’ current practices and help enhance operations through monitoring processes and improving outcomes. Ultimately, by using advanced analytics, companies within the manufacturing industry will gain a detailed and balanced view on labour activities, which will enable them to boost performance and drive sales.

Gregg Gordon Gregg Gordon, author of ‘Lean Labor’ and Senior Director at Kronos Incorporated, has led a successful career in enhancing operational efficiencies for manufacturers over the last 20 years. Gregg currently leads awareness-building efforts for the manufacturing market at Kronos Incorporated and boasts strong experience in leading strategic workforce management initiatives, both in the US and international markets.

For further information visit: www.kronos.com

www.manufacturing-today-europe.com 13

From idea to

reality A new project at a landing and braking systems manufacturer required a sophisticated IT solution to streamline processes and increase efficiency

Our products are developed in a cross-cultural, multi-site environment by technicians and engineers working in different countries who do not necessarily speak the same language and who, in the past, were using different methods and tools

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bout 25,000 Messier-Bugatti-Dowty equipped aircraft make over 40,000 landings every day, all over the world. Its dedication, global expertise and technological breakthroughs in aircraft braking have made Messier-Bugatti-Dowty the world leader in landing and braking systems. Its carbon brakes are 50 per cent lighter than older generation steel counterparts.

Airlines save on fuel through new composite materials, including titanium, used for machining equipment and landing gear, thus reducing their weight, environmental impact and operating costs.

These achievements reflect the technological breakthroughs of this company at the forefront of innovation. “Responding to a specific market requirement always means a new technological challenge,” said Naoufal Hadi, PLM competency centre manager (Product Lifecycle Management), Messier-BugattiDowty.

In 2012, the company launched a Manufacturing and Engineering Data System (MEDS) project to streamline development processes by rationalising information systems at landing gear production sites.

“Our products are developed in a cross-cultural, multi-site environment by technicians and engineers working in different countries who do not necessarily speak the same language and who, in the past, were using different methods and tools,” Hadi said.

“As our sites in Gloucester (UK), Montreal and Toronto (Canada), and Bidos (France) each had their own industrialisation processes and tools, data exchange was difficult and collaboration practically nonexistent,” continued Pascal Tavernier, MEDS project manager, Messier-Bugatti-Dowty. The MEDS project defines production processes, possible alternatives, as well as the manufacturing resources needed and requisite instructions. “One major challenge was to streamline processes and work methods across our sites,” Tavernier said. “We chose Dassault Systèmes’ 3DEXPERIENCE platform to support our development processes because it provides us with a unique platform with data references for design, delivery and maintenance. This digital continuity ties all our sites together so that everyone is working with the same and most up-to-date product information with real-time accessibility,” Hadi added. “We have adopted a zero paper approach, which is an enormous time saver that improves our productivity

Case study and efficiency.” “Moreover, the 3DEXPERIENCE platform is industry-oriented and flexible because it provides the ‘out-of-the-box’ industry specific tools we need to manage the entire production chain,” Tavernier said. “We can easily customise some functions to incorporate our specific business practices and know-how.”

A shared business platform Messier-Bugatti-Dowty uses many 3DEXPERIENCE platform applications including CATIA for design, ENOVIA V6 for multi-site collaboration and digital product management, SIMULIA for digital simulation and analysis, DELMIA V6 to manage assembly plans and machining sequences, and 3DVIA to exchange information throughout its ecosystem and to generate client documentation. “All applications are completely integrated and fully compatible, which helps harmonise teamwork and streamline data exchange,” Hadi said.

The industry solution experience offers Messier-Bugatti-Dowty numerous advantages.

Design and manufacturing teams benefit from real-time multi-site collaboration since they share and exchange in reference to the same model, which accelerates the development process.

“We no longer need to email information back and forth so we are no longer hampered by the delays inherent to this type of communication,” Hadi added. “With development cycles becoming increasingly shorter, we need real-time access to product information across all of our sites to speed things up.”

Another advantage is improved adherence to the quality standards and regulations required in the aerospace industry. “We have traceability and can ensure that configuration management and our manufacturing and control files comply with aerospace regulations and quality standards,” Tavernier added. “Our next step in the mid-term?

To link DELMIA with Apriso to extend our use of the 3DEXPERIENCE platform to the workshop,” he said. “This will give us digital continuity all the way to the numerical control (NC) machine.”

continuity in action.” “Since 3D is a universal language, cultural and linguistic barriers no longer exist,” Hadi added. “We are not wasting time translating, explaining and ironing out misunderstandings. 3D helps designers to better visualise and understand the object they are creating. They can try out different options live before agreeing on the best solution.”

Messier-Bugatti-Dowty capitalises on its years of experience and uses the latest technologies to develop leading-edge products that have earned it the trust of its clients. Many airliner and helicopter manufacturers, including Airbus, Boeing, Dassault Aviation, Embraer, Bombardier and Comac, rely on Messier-Bugatti-Dowty braking systems and landing gear. Some Formula 1 racing teams equip their cars with these braking systems. “Our clients’ trust is in part linked to our capacity to innovate and to deliver quality products and services

within budget and to specification,” Tavernier said.

“Faced with the increasingly challenging demand for lighter and more robust systems, we must remain in tip top technological shape so that our response meets expectations. Helping us stay in shape is the unique partnership we have forged with Dassault Systèmes and what we’ve accomplished with its service organisation. They have been very attentive to our needs and have systematically proposed the best solution that provides us with the most benefit. The value of this relationship and what we’ve gained from the 3DEXPERIENCE platform helps ensure that we continue to be well-equipped to meet our challenges in the coming years,” he concluded.

For further information: http://www.3ds.com/ industries/aerospace-defense/

3D master as a reference 3D models, particularly production process models, play an increasingly preponderant role in the aerospace industry. “The 3DEXPERIENCE platform meets the need of a strong evolution in the aviation field where the 3D model takes a leading role in the industrialisation process,” Tavernier said. “The 3DEXPERIENCE platform’s 3D Master approach helps us accelerate our development cycle as it provides a single common reference, the 3D model. The 3D model as developed by the design office becomes the reference for all downstream production. The same model defines manufacturing process, methods, NC machine programming, as well as our control and inspection processes. It is digital

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The future of

manufacturing A vision for the sector by 2030. By Cerys Wyn Davies

A company that leverages the networking potential made possible through the internet of things, combined with the in-depth knowledge that is now available through data analysis, and the fresh possibilities brought by 3D printing, is a company which will remain ahead of its competition over the next decade

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new industrial revolution is underway; one that is blurring the boundaries between physical and virtual. By 2020, Cisco Systems estimates that 50 billion devices will be networked together over the internet of things, while SMMT research suggests that the global market for connectivity components and services for cars alone will be worth €170 billion.

These startling predictions bring to the fore one of the key issues that manufacturers should be thinking about today if the UK is to remain a competitive and healthy force in manufacturing in 15 years’ time. Progression in technology, particularly in networking and big data, is a global force that is driving dramatic change in the industry and manufacturers need to adapt to it now.

This change presents a number of opportunities, but only for those companies, which understand and embrace it. A company that leverages the networking potential made possible through the internet of things, combined with the in-depth knowledge that is now available through data analysis, and the fresh possibilities brought by 3D printing, is a company which will remain ahead of its competition over the next decade.

Businesses should be carefully considering ‘Industry 4.0’, the popular term of the moment, which describes intelligent factories that link every part of the value chain with wireless automation. Machines can be connected across multiple factories and businesses, with easy identification and correction of problems, and allow the ability to tailor products for individual clients without enormous cost. This will lead to collaboration with partners that large business wouldn’t have dreamed of five or ten years ago, including SMEs. Whilst larger organisations appear to understand the concept, smaller companies still have some way to go. It is not surprising that many mid-sized businesses aren’t yet familiar with Industry 4.0. However, there is a real need for education if SMEs are to play the role that is increasingly being predicted for them.

Of course, this new ‘connected’ form of operation comes with its legal challenges. If businesses begin to share trade secrets and confidential information in order to work together, it creates IP and data

Technology

Technology will not be the only driver of change: climate change and sustainability are likely to be powerful forces on how manufacturing develops by 2030

the customer is low. Increasingly manufacturers are moving to a ‘servitisation’ model where a product is loaned to the customer. In another example, Philips also allows organisations to rent lighting systems for buildings on a lifetime supply, service and replace basis.

However, the use of this data will also lead to serious data protection issues in relation to the data collected on consumers and how it is proposed to be used, and the legal system can be slow to keep up. It is a common dilemma; global business does things that set new standards which then become hard to change. Consider Facebook and how the German data protection authorities have been trying to have some input - it’s too late and they struggle to have an impact.

Intellectual Property protection issues which introduce a need for new contractual agreements that ensure valuable data and IP is protected.

Data The ability to collect, store and analyse vast amounts of data will transform what manufacturers can do in future. The total amount of digital data generated in 2020 is estimated to be 44 zettabytes. One zettabyte is equivalent to 1,000,000,000,000,000,000,000 bytes.

This volume of data will allow systems to monitor factories and diagnose faults, as well as giving manufacturers greater understanding than ever of their customers and what they require.

It will allow personalised services for customers, at low costs that would previously only have been possible for mass-produced items. Alongside the development of 3D printing, this has the potential to transform manufacturing.

3D printing can enable a more personalised supply chain and customised products. For example, HP offers a printer product/service which monitors ink levels and posts supplies when

In addition to data protection, these technologies also raise issues of protection and infringement of intellectual property. It is critical that businesses adopting new technologies are aware of the potential issues and adapt to deal with the challenges. In a future where manufacturers and retailers (Amazon recently filed a patent application in respect of equipping its trucks with 3D printers) integrate 3D printing into their production processes, IP rights owners may be faced with the same problems that the music industry encountered with the introduction of digitisation technology - trying to monitor what everyone is doing. Again the model will need to change, probably to a licensing model whereby manufacturers are charged for the right to use the design/other IP rights as opposed to the traditional product purchase.

raw materials that may become scarcer, while climate change brings the risk of weather-related disruption, higher energy costs, and the need to conform to increasing regulation.

New ‘circular’ business models are needed where products are reused and shared, repaired, upgraded and recycled, and technology will need to be developed to reduce the impact of manufacturing on the environment.

A recent report, ‘The UK in 2030: Key trends in manufacturing’ published by Pinsent Masons in partnership with Business in the Community, Cisco, Walgreens Boots Alliance, Anthesis Lloyds Bank and WSP, sets out of some of the key developments that will affect the manufacturing sector between now and 2030 and how we can respond to them. Technology will be at the heart of these developments, but we shouldn’t underestimate resources, demography, politics and climate change. Manufacturers should be considering how to adapt and embrace these developments now.

Cerys Wyn Davies Cerys Wyn Davies is Partner at Pinsent Masons. Pinsent Masons is a global 100 law firm, specialising particularly in the energy, infrastructure, financial services and advanced manufacturing and technology sectors. The firm is staffed by over 2500 people in total, including over 1500 lawyers and more than 400 partners. www.pinsentmasons.com

Environmental issues Technology will not be the only driver of change: climate change and sustainability are likely to be powerful forces on how manufacturing develops by 2030.

Many manufacturers are dependent on

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Modern manufacturing

challenges Why manufacturers need to change how they manage product profitability. By Tobias Tauber

M

anufacturers must address several conflicting requirements to succeed in today’s marketplace: increasing customer demand for new features and functions; tighter time windows for new products; volatility in materials and labour markets; and the availability of trusted suppliers in different regions to meet dynamic market needs.

All of these factors have a significant impact on product profitability.

To address these challenges, manufacturers must have the ability to closely manage costs across their product lifecycle. It requires a more different, more strategic approach to product cost management (PCM) but it’s one that can not only reduce costs but also accelerate their time to market and increase their product innovation.

Here’s how:

Global product development Many manufacturers are designing for the global marketplace such that a core design and components can be used in any geography, with customisations made to support local markets.

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This strategy requires that manufacturers understand the cost of feature tradeoffs necessary to do this profitably. Effective PCM helps decision makers quickly assess the cost tradeoff implications of different product variants at the complete product, functional group or individual component level. This is especially beneficial when de-featuring a product for an economically sensitive market.

Achieving cost targets for new product development Manufacturers consistently miss cost targets on new product development programmes. In response, many conduct painful, time-consuming and expensive value engineering processes to squeeze cost back out of products after they’ve entered the market. Product development leaders need to be able to calculate and assess cost from the earliest product concepts – before unnecessary costs get built in. With the right PCM tools, programme managers, engineering, sourcing and manufacturing personnel can quickly and precisely determine the cost of a new part or

complete product design in real-time. They can also roll-up the cost of an entire complex Bill of Materials, including the cost of carryover parts that have costs stored in other enterprise systems.

Developing more innovative products Product innovation is a key determinant for many manufacturers’ competitiveness. Yet, often, companies are forced to limit the amount of product design work they do because of the time it takes to estimate manufacturing costs for new designs. Effective PCM tools provide fast, detailed cost estimates in real-time as a design changes.

This rapid feedback enables engineers to develop and evaluate many more design alternative designs, and improves their ability to develop a more innovative design that adds greater value for the end-customer.

Maximising product profitability Most companies are cost optimising a small percentage of the products they design, manufacture and sell. There are simply not enough resources available to manually cost

IT in manufacturing

s

and MES systems into a single repository that is accessible by anyone that needs it. And access can be managed as needed for different users.

Accelerating time to market

large numbers of new parts moving through the organisation. Those that have dedicated cost engineering teams typically focus on the most expensive, highly engineered parts. There are PCM solutions available today that enable companies to dramatically increase the percentage of cost optimised parts in new product designs and significantly improve profit margins. Manufacturers can also batch cost production parts and identify outliers where they may be overpaying their suppliers.

Aligning cost management goals for product development teams For most major manufacturers, cost data is scattered across the entire organisation in PLM, ERP, SCM and MES systems. This makes it very difficult to get a single consistent view of product cost. As a result, different departments and product groups each have their own, often conflicting, cost goals and agendas. Ultimately this yields a sub-optimal profit margin. With the right PCM solution, manufacturers can integrate all the cost data scattered among their PLM, ERP, SCM

Most manufacturers rate being first to market as one of the most critical aspects in whether a product will ultimately succeed. Companies that source a significant amount of product from their supply chain often experience delays waiting for a quote on a new product design. Effective PCM helps manufacturers stay on schedule and accelerate their time to market by enabling users to generate detailed product estimates in seconds or minutes versus waiting hours or days for a quote to come back from manufacturing, purchasing or an external supplier.

Enabling more flexible supply chains Manufacturers that operate globally know how volatile material and labour markets can be. This can create difficulty in weighing important Make vs. Buy decisions or comparing suppliers in one region vs. another. The current wave of re-shoring has elevated this challenge even further and the decisions a manufacturer makes have significant implications on profitability and time to market.

Effective PCM tools leverage comprehensive cost data from around the world to enable users to quickly assess the tradeoffs of different manufacturing choices: in-house manufacturing vs. suppliers, supplier A vs. B, region A vs. B. Proper analysis will include important details such as costs for materials, labour, overhead and manufacturing.

Summary Best-in-class manufacturers are differentiating themselves from their competition with a systematic approach to product profitability. They are leveraging new product cost management tools that equip employees to remove costs at every opportunity and gaining real advantage in the form of improved profit margins, increased product innovation, faster time-to-market and improved product quality.

Tobias Tauber Tobias Tauber is a Senior Business Consultant at aPriori. aPriori software and services generate product cost savings for discrete manufacturing and product innovation companies. aPriori’s real-time product cost assessments provide informed decisions at preand post-production, enabling manufacturers to launch products at cost targets, maximise savings in re-work projects and avoid overpayment of sourced parts. www.apriori.com.

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The

lone

danger Paul Smith examines the era of the ‘Lone Danger’ and uncovers the silver bullet: a smart telecommunications partner

Technical training is important at the launch phase, but also throughout the life of the equipment to provide information for new employees as well as refreshers for existing staff

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hilst manufacturing and production environments present the most obvious risks to workers that operate alone in remote locations, the welfare of the ‘accidental’ lone worker remains a common corporate oversight. With new UK legislation imposing fierce criminal penalties on organisations that fail to protect their employees from risk, companies are slowly recognising the need to take serious steps to protect the everyday adventures of all employees working in isolation – however brief their solo engagements may be.

The number of people in the UK classified as lone workers is growing rapidly. Some work in hazardous environments such as oil or gas refineries, others work in isolation within manufacturing plants, factories or construction sites. And outside of these, countless employees work alone in high-risk or perilous conditions at unsociable hours. However, whilst their place of work may be remote, their status as lone workers is often obvious and defined by their job specification. As such, as employers strive to meet their duty of care responsibilities in line with evolving HSE regulations, remote employees and contractors are increasingly being equipped with lone worker solutions to assure optimal communications throughout the working day. With

estimates suggesting there are now more than six million lone workers in the UK, it’s reassuring to know that their safety is being supported by the effective deployment of innovative communications technologies.

But what of the additional millions of employees that, through the course of their everyday routines, are exposed to similar periods of isolation – yet their vulnerability is disguised by a job description that does not reflect the reality? The UK workforce is full of ‘accidental’ lone workers whose jobs make them susceptible to the inherent risk of lone working by stealth – but whose employers are oblivious to the potential dangers. A company’s failure to be alerted to an emergency situation and to escalate and respond to it appropriately can have dramatic – potentially fatal – consequences.

With the recent introduction of the Corporate Manslaughter Act, the first prosecution under which related to a lone worker, organisations know that they are ultimately responsible for the safety of all their employees – and that their ability to protect lone workers, both atypical and ‘accidental’, is imperative. The penalties for neglect are severe. The maximum punishment is imprisonment, with business owners fully accountable. The financial repercussions are similarly significant – with fines of up to ten per

Lone workers cent of turnover for companies found in breach.

The human costs of a serious, but avoidable incident in the workplace are unquantifiable.

Alarmed? Perhaps you should be. Literally. Or at the very least, some of your employees should.

Masked identity So what constitutes an accidental lone worker?

The answers are variable and range from those involved in the palpably perilous to the seeming trivial. For example, manufacturing environments have clearly defined locations where lone working takes place, but when visitors or site managers journey into these hazardous areas, they too become potential lone workers. Likewise the colleagues who arrive at a production site as a pair but whose activities take them to different locations. Or the boiler repairman whose apprentice leaves him alone with an angry customer whilst he visits the wholesalers for a spare part. In each case, the considerations are simple: what happens if an inadvertent lone worker suffers an accident or incident? And what systems are in place to alert colleagues and escalate a response? If the answer is ‘none’, how will anyone know that an emergency situation is unfolding and respond to it quickly and appropriately?

The scenarios are not limited to remote locations. For example, during shift work at unsociable hours a shift co-ordinator or duty manager may arrive on site half an hour early and leave an hour later – potentially exposing solo staff to unmonitored risk. Conversely, many businesses have staff who arrive early in the morning to beat the rush hour traffic and work alone until colleagues turn up some time later. Similarly, many field-based executives meet at head office at 8am and do not return until close of play - but unless companies have got an effective workflow management tool or constant communication, how do employers know what is happening to their field-based workforce in the intervening period? In many companies, a continued reliance on primitive paper-based records, electronic calendars or whiteboard day planners provides an inadequate and passive means of tracking employee safety.

Howdy partner The solutions to the problem are out there and are often simple and inexpensive. But given the widespread variability in operational environments, a one-size-fits-all approach to protecting lone workers does not exist. A sensible approach is for senior executives with responsibility for operations or health and safety to take ownership of the issue, and conduct a collaborative, risk-based audit of common workforce activity to identify needs and areas of exposure. What are the

realities of your working environment? What risks are employees exposed to? If something should happen to them, how would you know? Could your business be unconsciously operating with accidental lone workers? Do you know who they are and are you doing enough to protect them?

A knee-jerk response is to look for a productbased solution to the problem. As lone working increases there is a wave of low-cost alarms and devices flooding the market. But in the era of the Lone Danger, it’s no surprise that there are cowboys out there offering cheap solutions that are neither fit for purpose nor aligned with real-world business needs. The best solutions go beyond an off-the-shelf product. Before going anywhere near procuring a solution, businesses are best advised to identify a trusted telecommunications partner that can conduct the appropriate needs analysis to customise a solution that best fits requirements.

The options are both varied and diverse, comprising tools, systems and methodologies that cover the full gamut of high, medium and low-risk environments. For example, organisations are increasingly deploying lone worker tools that align with consumers’ growing appetite for mobile technology – and building solutions that capitalise on the trend towards Bring Your Own Device (BYOD) methodologies. But BYOD is just one of myriad opportunities to create lone worker solutions that reflect the needs of all stakeholders.

It’s only through developing a full understanding of business needs that companies can identify the best-fit solution to suit budget and deliverables.

It’s important to seek expert advice. The range of mobile solutions – whether smartphone, radio or DECT system – is wide, but not all lone worker tools are compatible with every mobile device operating system. Seeking the counsel of a trusted telecommunications partner can help businesses review available solutions and make an informed choice.

The benefits of optimal lone worker solutions are considerable. Beyond the obvious advantages of mitigating risk and enhancing employee safety, there are clear efficiency and productivity gains that ultimately yield returns on the bottom line.

In some organisations, management has adopted a ‘buddy up’ approach to remote working to reinforce safety. This is undoubtedly expensive and can damage operational productivity. Effective lone working systems can certainly help address these inefficiencies. Moreover, a reassured and protected workforce is also a motivated one – and this, once again, can only lead to productivity gain.

However, it’s important to look at the bigger picture. Whilst companies are increasingly deploying lone worker solutions, many make the mistake of looking at the problem in isolation.

This is potentially expensive and can become

a catalyst for inefficiency as companies fail to optimise existing technologies. Investing in a lone worker system is not always necessary – the solution could simply be a case of making existing infrastructure work smarter. This reinforces the value of a good technology partner that can work with a business to understand their safety and efficiency requirements and design an integrated telecommunications strategy that aligns with business needs. A good partner cannot only help companies work smarter, it can help them buy smarter too.

Silver bullet And so as UK businesses face up to the reality of the Lone Danger, as well as their duty of care to employees in an increasingly regulated workforce environment, the need to equip both actual and accidental lone workers with the most appropriate systems of communication is considerable. The silver bullet is that with good advice, the right partner and a full understanding of your real-world workforce environment, businesses can enhance employee safety quickly, efficiently and cost-effectively.

Paul Smith Paul Smith is ANT Telecom’s Managing Director.

ANT Telecom is an automated communications specialist, that enables organisations to better protect their employees and business through state-of-the-art integrated communication systems for lone worker safety, asset tracking and productivity monitoring, all designed to help reduce downtime and increase profitability of their business. For more information visit: www.anttele.com

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Need to

know Crispin Kenyon and Zoe Harris discuss the new health and safety sentencing guidelines and their implications for the manufacturing sector

Given that British manufacturing is on the rise and the sector typically has a higher risk of accidents, it is essential that companies have a working knowledge of relevant health and safety legislation and the new implications of failing to maintain safety standards

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he Sentencing Council is due to publish new guidelines for corporate manslaughter, health and safety and food safety cases by the end of this year. The guidelines are likely to have a dramatic impact on the level of fines imposed on businesses and the likelihood of custodial sentences for individuals such as company directors is set to increase. Higher fines tend to attract greater media interest, with further unquantifiable reputational damage. Given that British manufacturing is on the rise and the sector typically has a higher risk of accidents, it is essential that companies have a working knowledge of relevant health and safety legislation and the new implications of failing to maintain safety standards.

Implications for businesses The proposed guidelines apply to organisations breaching sections 2 (duties of employers to their employees) and 3 (duties of employers to persons other than their employees) of the Health and Safety at Work etc. Act 1974 and breaches of health and safety regulations. For any business with an annual turnover in excess of £50 million the new norm will be fines of millions, rather than thousands, of pounds.

The stated aim of the proposed guidelines is ‘to ensure that all sentences are proportionate to the offence committed and in relation to other offences’ while following the principle that any fine ‘should be sufficiently substantial to have a real economic impact which will bring home to both management and shareholders the need to comply with the legislation and achieve a safe environment for workers and members of the public’.

The Council makes clear that the starting point for its recommendations is that any fine must reflect: the seriousness of the offence, the culpability of the offender and take into account the financial circumstances of the offender so that it meets, ‘in a fair and proportionate way, the aims of punishment and deterrence.’

Health and safety alarming results. A ‘large’ organisation is proposed to be one with an annual turnover of £50 million.

There are categories for medium, small and micro businesses below this.

An assessment of very high culpability with a high degree of risk created or significant harm actually caused will lead to a ‘large’ organisation looking at a fine on conviction of: l For corporate manslaughter £4,800,000 to £20,000,000 (starting point - £7,500,000) l For H&S offences £2,600,000 - £10,000,000 (starting point - £4,000,000)

For businesses, the guidelines recommend that a number of steps should be followed by the judiciary in determining sentence in each case.

Step 1 - will determine the offence category by looking at culpability and harm factors. In other words how serious is this offence taking account of matters such as the risk it created; how serious was any injury actually suffered; how far short of appropriate standards did the defendant fall, and how widespread was the non-compliance.

Step 2 - will focus on the turnover of the offending organisation to determine a starting point for the appropriate level of fine. It is anticipated that corporate offenders will be required to provide comprehensive accounts for the last three years to enable an assessment to be made of financial status. Normally, only information relating to the convicted organisation before the court will be relevant, ‘unless it is demonstrated to the court that the resources of a linked organisation are available and can properly be taken into account’.

The suggested ranges into which fines will fall depending on corporate turnover, leads to some

This is serious for business. Fines by law cannot be insured. Make no mistake, these fines are intended to be punitive, not to mention the stigma of being identified through a conviction as having caused an injury to or death of an employee. They come straight off the bottom line, as do the prosecution costs that on conviction are also normally ordered to be paid by a convicted defendant.

Furthermore, if annual turnover of the organisation convicted ‘very greatly exceeds’ £50 million, ‘it may be necessary to move outside the suggested range to achieve a proportionate sentence’. Logically it would seem that a business with an annual turnover of £100 million might expect to receive double these fine bands.

Step 3 - will involve a consideration of whether the fine suggested by steps 1 and 2 is ‘proportionate to the means of the offender’. This will allow the court to take into account: l The profitability of the business before tax, directors’ remuneration, loan accounts and pension provision, and l The assets of the business Those factors might push the suggested fine up or down, or might simply lead to the court allowing more time for payment, or for payment by instalments.

Step 4 - suggests other factors will then be considered that may warrant further adjustment of the proposed fine. If the organisation for example is a charitable or public body the fine is likely to be reduced if it can be shown it would have a significant impact on the provision of that organisation’s services.

Steps 5 to 9 - broadly set out matters which you would currently expect would form part of any reasonable plea in mitigation to reduce the penalty. This includes such matters as a discount for an early guilty plea, previous good record, and consideration of whether the total sentence is just and proportionate where more than one charge has been brought. There is also encouragement for consideration to be given, for example, to making a compensation order to anyone injured or damaged by the breach.

The final step suggests that there is an obligation for the court to give reasons for, and explain the effect of, the sentence on the convicted defendant.

Implications for individuals, directors and others The proposed guidelines apply to breaching sections 7 (employees at work), 36 (individuals) and 37 (directors) of the Health and Safety at Work etc Act 1974. The approach in the proposed guidelines is a retreat from the traditional sentencing regime and appears to increase the likelihood of custodial sentences for individuals such as company directors. For example, where the individual was negligent and committed an offence ‘through act or omission which a person exercising reasonable care would not commit’ but the offence involves the highest category of harm, for example, a fatality, the starting point would be a 26-week custodial sentence. The message of the Sentencing Guidelines Council is therefore clear – they mean business.

The development of the Sentencing Guidelines Council’s Guidelines are surely a reminder for any manufacturing organisation to review its approach to safety management, and to ensure it is supported by robust documentation, to minimise the risk of a health and safety related incident occurring.

When implemented, these guidelines will apply at the time of sentence (and not at the time the incident occurred), so insurers and their clients will also need to make careful and considered tactical decisions about case strategy to ensure minimal impact to the business.

Crispin Kenyon and Zoe Harris Crispin Kenyon is a Partner and Zoe Harris is a Solicitor at national law firm Weightmans.

Weightmans is a top 45 law firm with over 1300 people across offices in Birmingham, Dartford, Glasgow, Knutsford, Leicester, Liverpool, Leeds, London and Manchester. Weightmans is dedicated to providing results for its clients and success for its people. www.weightmans.com.

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Stadco

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A stamp of

success

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Stadco

Large mechanical press line located in Telford

Olympus Global

Olympus Global operate from a modern 38,000 sq ft purpose built facility located in the Black Country, the centre of Britain’s industrial heartland.

Through established world-class manufacturers we distribute OEM engineered, automotive components and assemblies.

Since 1974 we have developed, implemented and managed long-term partnerships with Stadco and other well-known OEM customers and their nominated tier 1 & 2 suppliers.

With two Mectron sorting machines, Keyence imaging devices and laboratory, we are totally committed to the everincreasing quality expectations of the automotive sector.

Our service is tailor-made to meet the specific requirements of each customer and the demands of their respective markets.

Continuous investment in people, facilities, equipment and service, drives Olympus Global forward to be a market leader in Kanban supplied automotive components.

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Stadco’s long and reputable history means that it is now in a position to reap the success of the extraordinary boom currently going on in the UK automotive industry

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Stadco Ltd Products: Manufacturers of steel and aluminium stampings and assemblies for the automotive sector Sites: Four www.stadco.co.uk

stonishingly, Stadco is able to trace its history back to 1812 making it one of the oldest registered companies in the UK. Over two centuries, the company has been able to develop and grow throughout an ever-changing UK manufacturing landscape and now occupies a position as a major tier one supplier to the automotive sector. Today Stadco’s core business revolves around the stamping and assembly of products from structural parts through to skin panels and complex assemblies, in both steel and aluminium.

With the automotive sector as its focus, business for Stadco over recent years has seen significant growth. Serving predominantly the UK and German industries, the company boasts blue chip names such as Jaguar Land Rover, Ford, GM and BMW on its client list, highlighting the reputation for high quality product and service the company has established over its long history. With a surge in growth in the UK market, driven by Jaguar Land Rover, Stadco has seen sales increase from £60 million to £230 million between 2008 and 2014. This looks set to continue as the company proves it is capable of supplying the increased demand. As Sales and Marketing Director, Dinos Andreou sums up: “We see the long term prospects for the industry as very positive.

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Stadco

One of two 4000 tonne transfer press lines recently installed in Telford

“We have been a proud supplier to Jaguar Land Rover for many years and our relationship with them is built on mutual trust and co-operation,” continues Dinos. “The last few years have seen unprecedented levels of growth and integration in working methods with their organisation.

“The unique range of large press line facilities that we have are highly compatible with Jaguar Land Rover’s in-house press shops allowing us to take

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We have a mix of long serving individuals plus a large influx of new employees who have joined us in recent years tooling from them with minimal or no adaptation work. The capacity this provides has been an important facet as their internal facilities come under increased demand through the combined impact of higher volumes and model proliferation.”

The core strength of Stadco is in its ability to supply a rapidly growing market through its people. “We have a mix of long serving individuals plus a large influx of new employees who have joined us in recent years,” explains Dinos. “These are all highly motivated and passionate with a clear understanding of what is required to meet and exceed our customers’ needs. This is our key strength.” Complementing this is a unique range of manufacturing facilities and capabilities spread out across the UK to best serve its UK customers.

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Stadco The Telford premises

Extra Personnel

Stadco have had a successful working partnership with Extra Personnel for over six years, in particular supporting the significant growth for Telford. They recruit for a wide variety of positions including press operatives, CMM programmers and supply chain managers. Extra Personnel’s Shropshire office has expanded with Stadco, having recently been refurbished and doubled in size. They interview manufacturing candidates daily and also run job fairs and assessments days for volume recruitment campaigns. Extra Personnel’s innovative approach and lean practices compliment Stadco, the team work closely with our management team to ensure the needs of the business are continuously met.

Profil

Profil, part of Penn Engineering, has had a long and mutually successful relationship with Stadco for over 18 years, starting with BMW Mini and now through JLR projects. As the world’s leading developer and supplier of mechanically attached fasteners Profil takes a system supplier approach including fasteners, feeding equipment and installation tooling to enable stamping manufacturers to integrate fasteners into their customers sheet metal components. Profil is able to supply nuts and studs capable of working across a range of materials from aluminium to ultra high strength steel and even in CFRP and other composite materials.

Dinos outlines the company’s production capacity: “We have four sites in the UK, three of which are located in the Midlands and one in Powys – thus providing us with convenient access to the UK’s automotive OEMs. Within the group we have more than eighty presses with a range of capability to cold form everything from a bracket to the largest panels on a vehicle.

A particular niche of Stadco is our capability to produce skin panels, which is normally regarded as a core competence of OEMs and retained in-house. We also have more than 25 years experience in stamping aluminium. Aluminium is now widely applied in the automotive industry and its use is forecast to grow significantly. We are ideally placed to benefit from this. Complimenting this is our experience and capability to assemble

complex modules, up to complete body structures in both steel and aluminium. Across the organisation we employ a wide range of technologies including in-pressing nutting, spot and mig welding, robotic roller hemming, self-pierce riveting, powder coat, electro coat and adhesive bonding.”

In order to keep up with the extraordinary levels of growth in the market, Stadco has invested

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Stadco Product range

FAGOR ARRASATE

FAGOR ARRASATE is a world specialist in design, manufacture and supply of forming machine tools, from presses and complete stamping systems to lines for manufacturing, processing and cutting sheet metal or special complete lines for manufacturing complex sheet metal parts. With six plants worldwide, the company has a global market presence and sells its products to 70 different countries. Founded in 1957, it is now the industry leader in number of lines installed, prestige of its references, technology, quality, research and development.

Practically, all the world’s top automotive makers, stampers, manufacturers and processors of coils and blanks in steel or aluminium, home appliances, metallic furniture, forged parts or electric rolled steel have FAGOR installations.

I.Rob (UK)

I.Rob (UK) Ltd has been supplying innovative engineering solutions to Stadco for over 15 years. Central to this is the provision of complete turnkey solutions from system design, manufacture, installation and commissioning through to ongoing production training and site support.

I.Rob has partnered Stadco on numerous projects ranging from tooling fixture design and build to fully automated robotic assembly cells incorporating the latest manufacturing processes.

Together the two companies have developed an industry leading electrical & mechanical set of standards that have been successfully integrated into the latest set of BIW assembly cells.

I.Rob (UK)’s dedication and commitment to each and every project has ensured that it maintains the status of preferred supplier within the Stadco Group.

around £70 million into its UK operations over the last six years. “As we emerged from the recession in 2008 we quickly recognised that the prospects for the UK automotive market were set to improve. Therefore, we undertook a strategic review of our entire operation, including detailed customer feedback, as to which market segments we should focus our attention on. One of the key outputs of the process being clear direction that we should concentrate on the manufacture of large stampings and complex assemblies,” outlines Dinos.

In 2011, the company acquired an 18-acre facility in Telford, which included two large highspeed mechanical press lines, a fully equipped tool room and 20,000 square metres of covered factory area. Subsequent investments were made in two leading edge transfer press lines, each capable of delivering a press force up to 4000 tonnes. “The initial line was installed during 2014 and the second is currently being commissioned,” notes Dinos. “Our projections already see both lines fully utilised. Another example is our facility in Shrewsbury, which saw the installation of a fully flexible cross platform assembly cell during 2014, which manufactures complex rear floor assemblies across four Jaguar Land Rover vehicle models. This equipment is capable of producing up to 260,000 complex assembles per year and can accommodate any variation in the build mix.

“Underpinning all of the expenditure on facilities and equipment is our continuous investment in people and processes. We strive to become a

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Underpinning all of the expenditure on facilities and equipment is our continuous investment in people and processes Learning Organisation, to continuously transform ourselves and our processes,” highlights Dinos. “As organisations grow, they can lose their capacity to learn as company structures and individual thinking becomes rigid. When problems arise, the proposed solutions often turn out to be only short-term and re-emerge in the future. Therefore, to remain competitive we need to find ways of working more effectively. To do this we need to learn faster than our competitors, we need to maintain

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Stadco Konecranes

Konecranes UK Industrial Crane Division, East Kilbride, is supplying a specially designed crane for the existing Stadco factory at Telford. The 40 tonne crane will run on existing rails at 25.9 metres span and will incorporate many design features of Konecranes CXT range of cranes.

The crane will be fitted with KONECRANES DynA range of Invertor speed control on all motions, floodlights, cable chain cross crane cable system, DynaHoist and REMOX radio control with back up pendant along with ControlPro Condition Monitoring. The crane also has Konecranes’ TRUCONNECT Remote Monitoring service where the crane’s performance is being continuously monitored remotely.

Graduate learning on the job

knowledge about new products and processes, understand what is happening in the outside environment and produce creative solutions using the knowledge and skills of all within the organisation.”

To achieve this level of continuous learning, the company places a major focus on collaboration, communication and trust throughout its workforce to develop and maintain an obsession with continuous improvement. A major part of this is making sure that the working environment is perfectly suited for individual learning and to encourage and facilitate its people to develop.

With people as such a central and driving force at Stadco, the company invests £500,000 annually in training and development throughout the organisation. Dinos sums up some of the initiatives employed by the company to facilitate this. “We work with the Institute of Leadership and

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Among the highlights will be a demonstration of Hexagon Metrology’s 360˚ SIMS complete solution for fully-automated dimensional process and quality control. There will be presentations by auto industry specialists plus a tour of the centre. The event takes place in Wetzlar, Germany, from September 30-October 1.

Register at www.hexagonmetrology.de/eng/automationforum

Management (ILM) to train in partnership with the EEF (Engineering Employers’ Federation) eighty first-line managers to deliver enhanced leadership and management skills. This is then accompanied by further ongoing skills development to enhance essential management skills for one hundred staff, delivered by the EEF. We have joined the EEF national engineering apprenticeship scheme with a 2014 intake of eight new engineering apprentices, and are participating in the new advanced ‘Trailblazer’ apprenticeship programme as well as implementing undergraduate and graduate schemes.

“We run a comprehensive and disciplined personal development review process for all employees to recognise both specific targets and behaviours, and a business wide programme of Six-Sigma learning and professional qualification support for individuals. To top this off the company also runs legal compliance training and support employees seeking external educational enhancement including programme management, MBA and IOD sponsorship.”

With this programme of individual continuous improvement in place, Stadco is well placed to respond to particular market challenges surrounding talent. As Dinos points out: “There is a key challenge in finding skill in the market at the moment; to recruit, train and retain the very best people. The automotive industry and wider economy has been slow in reacting to this shortfall in key technical skills, although there is now recognition at a national level and a real push to address the issues.” With its unique and

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Stadco

Shrewsbury robots

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We are continually seeking to challenge how far we can push beyond the business plan

Mitie’s Roofing Refurbishment Contractors

Mitie’s Roofing team are the largest commercial roofing contractor in the UK with unparalleled regional coverage, so they can provide a local service from local offices, with locally employed labour.

Mitie Roofing are an award-winning commercial roofing company and pride themselves on delivering a world-class service to every customer. They have an outstanding record on health and safety as well as all the accreditations needed to deliver a service safely and to the highest standard.

Mitie’s relationship with Stadco began in 2012 when asked to refurbish the main office roof that was in desperate need of repair. Following our works Stadco’s Engineers had a dry place of work to plan their production facility.

Since then the relationship has developed further and Mitie regularly undertake roofing refurbishment across three sites, namely Telford, Shrewsbury and Llanfyllin.

The basis of the relationship – trust, safety, quality and value.

exemplary structure of personal development and opportunity provided, Stadco reports that it is successfully establishing itself as an employer of choice with people actively approaching the company.

Elsewhere in the market, Dinos sees continued opportunities in the rising growth of the UK automotive industry. “Our assessment is that there remains a significant shortfall in both stamping capacity and available assembly footprint to satisfy projected vehicle production demand in the UK. Stadco are well placed to benefit from this opportunity providing we continue to invest and satisfy our customers’ needs,” he says.

“We are currently in the middle of an unprecedented schedule of new programme launches, so over the next 12 months, in addition to the ongoing strive to improve all areas of the business, the successful delivery of these programmes is a clear priority for us. More strategically, our current business plan sees the

company continuing to grow on a similar trajectory to that which we have experienced in recent years. Even with this continued level of expansion we are far from complacent, continually seeking to challenge how far we can push beyond the business plan. Ultimately, however we recognise that long term continued growth is only sustainable with a workforce which remains engaged and motivated.”

With the levels of growth that are currently displaying themselves in the UK automotive industry, the future for Stadco looks particularly

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Stadco

Castle Bromwich, one of the largest press lines in Europe

bright. The company’s unfaltering commitment to offering a fully integrated product service and its ability to develop and maintain strong collaborative relationships with its blue-chip customers has enabled it to occupy the position it now sits in. With this in mind it would be easy to expect the company to sit comfortably, yet it is clear that continuous improvement on individual, company and industry levels is a very obvious drive for Stadco not to sit still. “The organisation has been on a tremendous journey,” says Dinos, summing up the company’s current position. “We are very excited that the best is still yet to come.”

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Sulzer Pump Solutions Ireland

Improving the

flow

Sulzer Pump Solutions Ireland (SPIRL) benefits from the skills of a knowledgeable workforce

Sulzer Pump Solutions Ireland Ltd Products: Pump engineering and manufacturing Sites: Wexford, Ireland www.sulzer.com

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ulzer’s manufacturing facility in Wexford, Ireland has a rich and varied history.

The German company ABS Pumps, which had been manufacturing pumps and equipment for the wastewater industry since 1959, originally founded the site in 1973. By 2011, in a move to incorporate wastewater services into its portfolio, Sulzer acquired the company at that time called Cardo Flow Solutions and brought the Wexford site on board. Significantly, Sulzer brought to the table over 175 years of experience in the pump engineering and manufacturing industry. What results is a facility that has access to a vast expanse of experience and expertise within the industry, and this is very much reflected in the success the company has earned.

“In Ireland we focus primarily on the production of submersible pumps,” explains MD in Ireland, Juergen Deutschmann. “We support the municipal wastewater collection and treatment services, and

we are also strong in the domestic commercial wastewater segments.This includes products and service from initial collection to mixing and aeration within the treatment plant. Recently, after a footprint consolidation at Sulzer, we have also started producing pumps for the mining and construction industries.”

As a global organisation the Sulzer divisions Pumps Equipment, Rotating Equipment Services and Chemtech serve a wide range of industries. Within its pump offering, which accounts for more than 50 per cent of business, the company targets the oil and gas, power and water segments. “Wastewater was only introduced to Sulzer’s offering in 2011 and during the transition period the market did not offer any support, so we faced a number of challenges,” notes Juergen. “However, over the course of 2015 we have overcome these issues and are now experiencing some positive growth in the water segment.”

Left: Assembly area for Sulzer Dewatering range of pumps manufactured in Wexford Below top: Sulzer Wexford – Plant 2 building housing; main office block, pump assembly, machining, painting and shipping areas Below bottom: Section of paint spraying line at Sulzer Wexford

The strength of Sulzer in Ireland very much comes from the expansive global network and organisation. “The company works in many different strategic areas so all of that competence and expertise is brought to our products,” highlights Juergen. Another valuable capability offered by Sulzer that allows it to stand out is its approach to research and development. A product development (PD) team is located within the company, developing products and supporting the local and global organisation.

“We are fortunate to have a PD department in Ireland, supporting our products but also other products for colleagues around the world,” says Juergen. “A recent example of good collaboration is the introduction of a new progressing cavity (PC) pump line.This is a sludge pump to clear out

Roche Logistics Group Roche Logistics Group have invested over €10 million in recent years in our premises, fleet and computer systems, making us one of the most efficient third party logistics providers in the country. Over the last 20 years we have been committed to providing Sulzer Pumps with a customer focused solution that make their freight management and production line, user friendly, cost efficient & safe. With this close co-operation we believe we are an integral part of their production and success.

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Sulzer Pump Solutions Ireland

Bufab Ireland As Kevin Donnelly, managing director of Bufab Ireland explains, the transfer of Sulzer production from Nordmaling to Wexford was a perfect example of how Bufab’s global presence can provide benefits to its customers. “Bufab Ireland was able to supply all parts previously supplied to the Nordmaling facility by our sister companies in Sweden and along with these items provide further supply consolidation of another 400+ items to their facility in Wexford.

“Initially the project involved the transfer of 274 articles that were previously supplied by Bufab companies in Sweden directly to the Sulzer Nordmaling facility. Just one year on and Bufab Ireland are now supplying close to 700 articles to Sulzer Wexford via our Kanban VMI solution from our warehouse in Wexford. The range of parts supplied include standard fastener items along with branded distributed items, electrical and mechanical parts, rubber and plastic parts and also some items that were previously assembled in house at the Sulzer Wexford facility. We also worked closely with Sulzer to assist them with the design and set up of the new production line for the transferred production from Nordmaling.

“Within Bufab we refer to the above as ‘Global Parts Productivity’ or ‘GPP’ and we feel honoured that Sulzer Pumps Ireland has given us this opportunity to put ‘GPP’ into action at their Wexford facility. We are still working daily with the team in Wexford to consolidate the supply of further items which will bring benefits to both companies and certainly helps to demonstrate the core values of Bufab being put into practice as ‘Dedicated, Trustworthy, Solutionists’.”

Above: Cut through view of submersible pump from the Sulzer XFP range Right: XJ Submersible Drainage Pump – manufactured in Sulzer Wexford

Sulzer Wexford product Sanimat 100 Lifting Station

what is left after the water has been removed from the water treatment plant. Another excellent example of innovation achieved through global and local collaboration is the recent completion and introduction of the Contrablock plus hydraulic range on our large wastewater pumps.This involved PD, procurement and operations in Lohmar, Germany and Wexford working closely together to deliver a successful innovation to the market.”

As part of a world-leading organisation the Wexford-based factory operates to a level of product quality and reliability that conforms to the global reputation held by Sulzer.

To adhere to this there is in-house production of hydraulic components to maintain these levels. “We still machine components on-site especially for parts that are individually complex, so it is key to keep these manufacturing capabilities internal,” notes Juergen. “However, our main focus in Ireland is on the assembly and testing of products. Amongst other facilities we have a dedicated PD test department with capability for motor brake testing up to 45kW and a dedicated anti-clogging test tank, which includes a 1000 fps high-speed camera to visualise material

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Sulzer Pump Solutions Ireland

interaction with pump hydraulics.These are key core competences for our business. It has also recently completed an investment programme to install a new robotic paint line to deliver a high quality finish to the company’s products.

“We are much focused on lean production and have a global lean organisation set up to ensure that this is delivered in our facilities,” adds Juergen.

“This is about making sure that everybody in the factory understands the lean process, so that we can operate in a more organised and harmonised way. Ultimately, the organisation is looking at best practice – we don’t have to reinvent the wheel – and making sure these practices are delivered in all the right areas.”

As part of this focus on lean manufacturing, the Wexford facility has invested heavily into the new production line for mining and construction products. “We have utilised a new shape of production line in order to improve the manufacturing flow, reducing disruptions, recording and resolving problems and improving our first pass yield,” outlines Juergen. “We have invested into new workbenches, which are organised to ensure a constant flow of work from station to station. All

parts needed are already there and we have ensured there is a lot of transparency with things like pictures to make information clear about what is being done at each station.This is then accompanied by IT equipment to allow scanning and tracking to be monitored by everyone. Essentially, this is a demonstration of our lean capabilities that will be considered for a roll-out across the factory.”

Results from the new production line are already beginning to show as Juergen reports a 50 per cent increase in output within just a matter of months, yet he also remains aware of the dangers in becoming complacent with this type of achievement. “To truly be lean it is a programme of continuous improvement,” he says. “Therefore we have improved our communication methods with the introduction of our one minute boards to the production lines to make sure everyone is aware of where we are and where we want to go both internally and as a part of Sulzer. We also have a number of key performance indicators (KPIs) in

Sulzer Wexford main entrance and security office

place to make sure we can track exactly where we are and see where we need to improve.

“We have quality and reliable products already but we would like to further reduce costs and use our global footprint to participate more in the market,” concludes Juergen. “In addition to this strategic goal we will also be focusing on growth areas like the increasing demand for municipal wastewater systems and opportunities in the mining and construction segment.”

NSK

NSK is one of the world’s leading manufacturers of rolling bearings, linear technology components and steering systems, and is a key supplier to the pump and compressor industry globally.

NSK has provided Sulzer Pumps with bespoke bearing solutions for their range of submersible pumps for over 15 years. Working closely with their design engineers, NSK has provided engineering expertise, together with production planning and logistics support to ensure quality product is delivered on time.

Reliability and long life are key requirements for submersible pumps, and bearings are critical pump components. Innovative NSK bearing designs such as the unique DDU ball bearing seal, high performance ENS grease and high load capacity HPS series angular contact ball bearings have all contributed to the outstanding reliability and long life of Sulzer’s submersible pump range.

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Collini

A strong

coating As it continues serving the market with a robust reputation, leading surface treatment company Collini is establishing strong manufacturing processes to keep up with growing demand

Collini GmbH Products: Provider of surface treatment solutions for metal and plastic Sites: 12 www.collini.eu

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ith 115 years of history behind it, it is no wonder that family-owned Collini GmbH is a leader in the European surface treatment industry. Through a series of acquisitions and successful organic growth, the company now operates from 12 sites in Austria, Switzerland, Germany, Italy, Romania and Russia, employs 1400 people and last year turned over a record 181 million euros in sales. Split into three divisions Collini specialises in electroplating, hot-dip galvanising and powder coating to offer a wide range of surface solutions. This is then enhanced by a heavily customer orientated service to innovate and develop new solutions to improve customers’ products.

Indicating the sheer volume of Collini’s operations and recent success are a number of

facts. Last year the company used 4000 tonnes of zinc, 600 tonnes of nickel, 1000 tonnes of copper, 200 tonnes of powder and paint, and 200kg of gold to facilitate a broad range of applications. As such, it delivered 200 million kilograms of parts to over 6000 customers and its trucks distributed products over a distance of five million kilometres.

The company’s stated goal reads: “The ultimate satisfaction of the specific needs of our customers. We do not sell products; we offer complete and target-orientated applications.”

By understanding its customers’ needs, Collini heavily focuses on assisting and challenging its customers to help improve their competitiveness in their respective markets. With a commitment to continuous improvement it also ensures to learn and adapt to further its lead in surface technology. To facilitate this development Collini operates around a set of core values: diversity of people, partnership, product innovation, social responsibility and ownership.

Innovation is a key part of Collini’s operations and CEO, Johannes Collini highlights his personal commitment to ensuring this is driven by the

company: “I see my task to develop visions, formulate clear objectives and to take the right measures to achieve them,” he says. “When we develop new solutions, the company relies on the co-operation of universities in Kiev, Moscow and Copenhagen, as well as a research centre in Wiener Neustadt.”

One example that particularly demonstrates the level of highly technical innovation delivered

by Collini has recently gained a very high profile. The European Space Agency’s Rosetta

IMR Metals (Metal Powder Technologies GmbH) IMR has been established as company for 25 years.

During this time it has developed into the leading supplier of industrial metals and semi-finished products, which it markets globally.

Active advice and supervision of suppliers and customers is the guarantee for securely supplying its business associates at a high quality level. IMR’s expertise is in the procurement, refinement, inventory holding, financing and hedging of raw materials and metals.

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Collini

spacecraft, which dropped the Philae Lander on to a comet in November 2014 after over ten years of travel, incorporated surface technology provided by Collini. Several components of the probe’s ‘Rosina’ spectrometer were made from a special titanium alloy and coated in gold by Collini. The gold coating on the surface provided the functional qualities demanded by the extremities of space travel in terms of conductivity and protection against thermal radiation. During the development of this specialist coating, Collini’s product underwent numerous tests to guarantee a successful mission in extreme temperatures under a vacuum.

To achieve this level of flexibility and also keep up with growing demand in the market, the company has also invested in innovating its manufacturing processes. As such in Collini’s Biel factory, which processes electrical applications on four reel-to-reel plating lines, the company has implemented a five-day factory process on its journey to become a leaner company with shorter lead times. The five-day factory process ensures that products are processed and delivered in five days from the point of order. “We try to solve problems and not just offer products. We want to co-operate with our customers on a different level in order to be the best in this area,” explains Head of Plant Maintenance at Biel, Ivan Stojanovic. “The challenge here is that in order to implement the five day factory we need to think like a world

leader and consistently process products in an optimised way.”

This supports a programme of continuous improvement across the whole of Collini’s manufacturing capabilities, which includes over 60 automatic coating lines. By striving for lean manufacturing in all aspects the company is able to eliminate processes and adapt to invent new ways of meeting its customers’ requirements.

“Already today we are able to improve the throughput time considerably to provide optimum support for the customer’s site, to think innovatively and then offer to the customer according to their precise need. We guarantee our customers more than just high quality coating,” said Ivan.

With such a comprehensive product and service offering, Collini delivers a highly regarded solutions package to the global market. Since 1990, turnover has increased seven-fold from 25 million and employee levels have risen from 400 to 1400 in order to keep up with the company’s success. With a number of awards under its belt, such as the VN Economic Prize, awarded by the Vorarlberg state in 2015, and a reputable apprenticeship scheme in place, Collini’s growth and success looks set to continue. To achieve this the company continues its dedicated focus on driving innovation into the market, working towards a lean manufacturing process and delivering high quality products to its customers.

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Laufenberg

Sticking to its

values

As global demand for silicone coated release liners increases, Laufenberg’s commitment to continuous development puts it in a good position to secure a successful future

Laufenberg GmbH Products: Manufactures high quality silicone coated release liners Sites: One, Germany www.laufenberg.info

F

ounded in 1947, and moving into the production of silicone coated release liners in 1960, Laufenberg GmbH has climbed through the ranks to become one of the leading suppliers of release papers and films to a range of applications. With a focus on continuous development and a forward-looking approach to business, the company is now one of the largest family-owned manufacturing companies of release liners in Europe. In 2009, the company reached a significant milestone as it completed the acquisition of a competitor’s release paper business to bring on board a fourth coating line, and recently invested further into a new slitting and finishing building. Currently one of the coating machines for single side coating is being extended for double side release coating in one pass.

“The main customers for us are tape producers,” begins Managing Director, Jörg Soding. “Other major applications are medical, specialty graphics, composite and general industrial processes. Despite a diverse customer base the release liner is always used to cover an adhesive or resin. For example, the siliconised coating is used in the production of tape, including double-sided for applications like carpet installation, medical dressings and plasters, and composites.”

What sets Laufenberg apart in the market is the extensive range of products that it has on offer, and its attitude towards continuous development.

“We have a very wide offering of papers and films, with a variety of silicone coatings and release levels, which determines how easy it is to pull the adhesive layer off,” highlights Jörg. “With about 200 people employed here we have a lot of manpower working in quality control and a number of application engineers who work directly with customers and suppliers to develop the best and most appropriate products.”This ability to manufacture bespoke solutions for specialist applications is supplemented by the ability to process small production runs to suit the customer’s needs. “We are always trying to find the best solution for the customer,” he adds.

At present market conditions for Laufenberg are positive, down to a trend within the global industry to replace traditional processes with increasingly effective adhesive solutions. “We are currently experiencing an increase in demand across most of our sectors,” explains Jörg. “Use in medical applications is increasing, as it is in the composite industry with products such as lightweight carbon fibre for use in the aeronautic and automotive industries. More and more companies in many industries are turning to adhesive tapes as holding solutions over heavier screws.”

With demand increasing, Laufenberg is committed to maintaining its delivery of continuous improvement to bring to market a robust and competitive product offering. “One of our new developments, which is quite interesting, is our

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Laufenberg

Munksjö

Intelligent paper technology Munksjö is a world-leading manufacturer of advanced paper products developed with intelligent paper technology. Munksjö offers customer-specific innovative design and functionality in areas ranging from flooring, kitchens and furnishings to release papers, consumer-friendly packaging and energy transmission.

The transition to a sustainable society is a natural driving force for Munksjö’s growth as the products can replace non-renewable materials. This is what ‘Made by Munksjö’ stands for.

premium release product that has a very low release value against aggressive butyl rubbers as well as acrylic and rubber based adhesives.This makes it easier to release the adhesive from the liner where before the release force was not sufficient,” says Jörg.

Another significant development is the establishment of a dedicated medical line from Laufenberg, which adheres to a number of German and American medical compliances.

To facilitate this continuous development strategy

the company is currently in the process of upgrading the competencies of its coating lines. With four already in place, two were only capable of coating one side of the paper or film. “As an example, for label paper you only need one side to be siliconised because it is only that side that comes into contact with adhesive,” outlines Jörg. “However there are an increasing number of applications that require both sides to be coated, such as wound tape, medical, composite and industrial applications.The market demands from our customers are telling us that we need higher capacity to do two sides.Therefore, to react to this we are upgrading one of our lines so that we have three machines operating with the ability to coat both sides in one step.”

In addition to this a lot of attention is being focused on general efficiency improvements throughout the factory, as the company strives to achieve higher quality and higher speed with improved in-line control systems.The strategy currently being implemented with upgraded equipment aims to reduce setup times significantly.

The company is also looking closely at improving its internal logistics to better manage production flow across a number of sites. For instance, two sites that are separated by a busy public road have been connected by a fully automated transport system that bridges the two facilities.

The strategic vision for Laufenberg is centred on becoming the number one choice for more and more customers in silicone-coated release products.

To achieve this it remains committed to its values, and dedicated to innovation. “We try to be fast in finding out what customers want and fulfilling these wishes,” concludes Jörg. “Our approach is very much to continue having very close contact with our customers and maintain the conversation about how we can help them move forward. As a family-owned company we have a robust long-term thinking strategy, which starts with the product but is very much in line with the relationships we build with our customers over a long period of time. Reliability and long-term thinking typifies the way we operate.”

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Kel-Tech Engineering

The strategic

solution

Through years of supplying to major OEM brands in the UK and Ireland, Kel-Tech has developed a customer-focused strategy, which has lead to it being recognised as one of the top sub-contract suppliers in its industry

Kel-Tech Engineering Ltd Products: Contract manufacturer with core competency in sheet metal fabrication Sites: One: Waterford, Ireland www.keltechengineering.com 54 www.manufacturing-today-europe.com

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ounded in 1987 and experiencing positive growth for much of its history, Ireland-based Kel-Tech Engineering has been able to establish a strong offering to the market and position itself next to some major players in the OEM industry. With cut, fold, weld, pre-treatment, painting and final assembly facilities all under one roof at its 90,000 square foot plant in Waterford, Ireland Kel-Tech offers a one-stop-shop to its customers. Its core offering can be split into four ‘sweetspots’: Acoustic enclosures and bases; integrated fuel and hydraulic tanks; overhead guards and integrated cabins; and integrated electrical control boxes.

Over the last 15 years the company has been successful in serving blue-chip customers in industries such as power generation, material handling, automotive and screening and crushing but to name a few with high quality pressures being placed upon Kel-Tech, which the company

successfully met. As a result, up until the economic crash at the end of the last decade, Kel-Tech was riding a wave of exceptional growth.

“The environments that we supply to are very affected by the world market,” begins Business Development Manager, Seamus Lawlor. “So when we had booms in the 2000s we were growing exponentially with some of our big companies.

However when the crash came between 2008 and 2012, our customers lost a lot of work that we would supply to.” With some OEM’s turning to low-cost manufacturers in the Far East, in 2012-2013 Kel-Tech lost about 35 per cent of its sales in a short period of time. Emerging from the crash has been tough for Kel-Tech, as Seamus explains that its industries can be slow to recover, however he is pleased to announce that in the first two months of FY2015, the company is roughly back to where it was in 2012.

“This has been driven by our new strategy,”

‘‘

Kel-Tech’s semi & fully integrated products improve the end customers tact time, reduce the OEM’s cost of ownership related to the product and all importantly lessen the work load on the buyer whom now has a one line item order related to the part approached them with a brief. “We’re trying to offer a 360-degree service,” adds Seamus.

“This new strategy has generated a lot of interest in the market as it solves a lot of the capacity and cost problems experienced by our customers,” he expresses. “So capacity problems on their side and increasing their machine output really drove the strategy. It’s also easier on their buyer who now only has to order one finished item with a fixed lead time, and the cost of keeping stock is lower too.” This flexible change in

he outlines. “We now class ourselves as contract manufacturers, before we supplied a piece part; now we supply the part. In the last two years we have realigned our strategy in order to climb up the supply chain as manufacturers that can supply fully integrated components. For example, before we would have just supplied a steel fuel and hydraulic tank, now we’re supplying a fully integrated tank flushed for internal cleanliness, painted and fitted with filters, site gauges, manifolds and everything else, so it is effectively a plug-and-play product.” This integration spreads across its product range, as it now supplies fully wired and glazed forklift cabins, wired control boxes and fully foamed and silenced acoustic enclosures. The company has also been able to use its design skills to further enhance this offering as it has completed full cabins and acoustic enclosure redesign programmes from concept to production after existing customers

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Kel-Tech Engineering

strategic direction has arguably been crucial to the regeneration of Kel-Tech as it battled through the tough spells of recent years, and whilst it has enabled the company to regain its pre-crash position, it still sees a lot of potential to grow.

As such, the company is currently undergoing a rebranding programme and will soon be launching a new website to help generate further sales within the industry.

This move also opens up wider markets for future expansion potential. As Seamus explains: “There was a lot of competition out there for just the painted metal work that we were doing

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before, so it was hard for us to compete beyond the UK and Ireland. However, as we have move up the supply chain to offer a more integrated solution, and differentiated ourselves, I definitely see a market for Europe and beyond. At the moment though, we are focused on exhausting the UK and Ireland before we look beyond.”

Another part of the company’s ability to emerge from the recent crash with strong levels of growth is the existing knowledge and assets already invested in the business. “We sit in the fortunate position where we have very up-todate machinery that is capable of servicing our

industries,” continues Seamus.

“From a people point of view, we are also the first manufacturing company in our sector in Ireland to set up a City and Guilds training scheme to help enhance the skills we have on the floor.

As a result we have a lot of employees progressing their competencies to a high level.”

The future vision for Kel-Tech centres on a continuation of implementing this strategy and creating more awareness about its offerings.

“Traditionally we would have been seen as a supplier to our customer base,” Seamus concludes. “Now we want to be a strategic partner to them. So by developing our core products, we can be a strategic advantage to them with a 360-degree type service. By working with us our customers will get the very best products in those areas. Therefore, the future focus is all about aligning with the customers’ requirements and taking steps on this journey to become the strategic partner of choice.”

Skamol

Precision

insulation

Skamol is a leading supplier of a wide range of insulating materials worldwide

Skamol A/S Products: Thermal insulation materials Sites: Denmark www.skamol.com

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ith over a hundred years of experience in developing, manufacturing and marketing thermal insulating materials for heat-intensive industries and passive fire protection applications, Skamol A/S has established a proven track record with clients around the world. The business was established in the Limfjord area of north-western Denmark as Skarrehage Molerværk I/S during 1912, with the purpose of utilising the region’s deposits of diatomaceous earth in the production of insulating bricks. Diatomaceous earth is also known as ‘moler’ and the moler bricks produced

by Skamol were originally used in house building and chimney linings. In the wake of the Second World War the company began to increasingly focus on the industrial application of its products and since beginning as a local supplier of insulating bricks, Skamol has become a leading global

supplier of insulating materials worldwide.

Today Skamol operates as a highly regarded industry supplier to clients across a spectrum of business sectors including applications within the aluminium industry; hearth and heating appliances; high-temperature industries, such as the cement, paper, pulp, lime, iron, glass and ceramic sectors;

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Skamol

passive fire protection, for example core material for fire doors, heat protection shielding around fireplaces and stoves and mold protection. As the company’s scope of industry applications has increased, so too has the range of insulation products and solutions that it is able to provide.

Presently Skamol maintains four plants that produce insulation bricks and boards in moler, calcium silicate and vermiculite. Plants are individually dedicated to the production of moler, vermiculite and calcium silicate products respectively, along with a second plant geared to the production of moler bricks in Russia that was acquired during 2009. Further to the products it manufactures in-house, Skamol also supplies nitride bonded silicon carbide slabs produced in China.

Over the course of over a century of close co-operation with clients operating within a broad base of industries, Skamol has established a strong market presence throughout Europe and beyond and is keen to expand its market share in regions including Russia, China and the Middle East. One of the strongest areas of the business has been its presence within the aluminium industry, which has traditionally generated a significant proportion of the company’s turnover, as Holger Østergaard, Business Director Middle East and Africa elaborates: “The aluminium industry covers a major part of our business and has been its strongest industry for decades, because we started out very early in this sector.

Since the 1960s Skamol has kept close contact with aluminium smelters and consulted with the

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aluminium industry regarding how it could improve its business processes. Skamol products also happen to fit very well with the aluminium industry – the smelting process takes part at 960 degrees Celsius, while all of the company’s products have a maximum service temperature of between 900 and 1100 degrees Celsius. So the company’s strength in the aluminium sector can mainly be explained by an early start combined with wellfitting and effective products.”

Its proven knowledge of insulating materials and its strong links with the aluminium sector have allowed Skamol to acquire a significant market presence.

Throughout Europe and regions outside of China and Russia, Skamol has established a market share of around 65 per cent and is present at most of the market’s aluminium smelters. The company also maintains a strong and growing presence with Russia and is actively seeking to expand its activity with clients within China.

“What is special about the aluminium business is that there are relatively few customers on a global basis. In China there are just over a hundred smelters, while in the rest of the world – including Russia there are 91 active smelters presently. This makes the industry unique and as such clients in the western world and Russia know and trust Skamol. The company has worked with them for many years and maintains close co-operation through regular commercial and

technical meetings with all major players.

“Within Europe, Skamol has a market share of around 65 per cent and in Russia it is working to grow its market presence,” he continues.

“The big challenge for us is China, which can be a challenging market to approach due to factors such as product requirements, business procedures and language for example. Skamol has worked within this market for the past two to three years and undertaken visits with technology suppliers, trials and so on, but this is still very much in the early stages. In terms of demand it appears that the market is stable, in that the global demand for aluminium is increasing. So from that point of view it is a healthy growth industry. However, 90 per cent of that growth is

taking place in China, while the remaining ten per cent is in the rest of the world.”

While the company continues to develop its global footprint within insulation products, Skamol will also seek to expand its sales of nitride bonded silicon carbide bricks throughout its entire market base in order to facilitate further growth, as Holger concludes: “With a market share of 65 per cent it is challenging to grow, because clients may not want to put all of their eggs in one basket, while regions may also have import taxes etc that make it difficult to grow above a certain level. Therefore around ten years ago Skamol began to deliver traded products such as nitride bonded silicon carbide bricks and these have become very successful. The company certainly expects to continue to grow in this area.”

Palabora Europe Ltd

Palabora is the single largest supplier of vermiculite in the world and has enjoyed a long and successful relationship with Skamol for more than +20 years. The relationship remains very important today, as they continue to buy this high quality, versatile mineral.

Vermiculite is a hydrated magnesium aluminium iron silicate, which resembles mica in appearance. Its principle applications are in the construction market, where it is used as fire protection or as an insulator in plasterboards. For Skamol’s applications, vermiculite is used in moulded shapes, insulating bricks, mortars and aggregates. They have a highly respected brand and are a leader in this field.

Palabora Vermiculite

Palabora Vermiculite is a hydrated, magnesium-aluminium-iron, silicate, which resembles mica in appearance. When heated (exfoliated) expands into worm like particles which is the origin of its Latin name ‘vermiculare’.

Palabora Vermiculite is one of the single largest producers in the world for this mineral, which is mined in South Africa and transported to the different markets around the globe.

Performance in 2014 for Palabora has been good with increased volumes. Through various initiatives at the mine, Palabora hope to improve their product offering and package as they look to produce and sell more vermiculite in the future years.

To ensure Palabora has a sustainable business for the future they will continue to concentrate their efforts on safety, production stability and costs. This renewed focus will promote a good solid business through to 2033 and beyond.

Palabora are physically extending the area of mining and therefore prolonging the life of the ore body.

Palabora have long standing relationships with service providers and with their support and professionalism this will continue to make the Palabora vermiculite package one of the best.

Market development of new products/applications in vermiculite, has in recent years slowed down. Palabora are keen to engage with businesses that are willing to explore new areas on the benefits vermiculite could bring to the world. Vermiculite is such a diverse mineral with regard to its end use applications. The question is have we exhausted the list of end uses? Below are just a few of the applications that vermiculite is currently used in: • Animal Feedstuffs • Lightweight Concretes • Bitumen Coated Vermiculite Screeds • Loft Insulation • Fire Protection • Refractory Products • Friction Linings • Silicate Bonded Shapes and Blocks • Horticulture • Vermiculite Plasters • Insulation in Steelworks and Foundries The vermiculite market is a very niche market but its challenges and strategies are similar to other industrial minerals. The market is much more competitive than it was 10 years ago and the Palabora product offering has had to improve to ensure Palabora keeps its place as one of the most sourced vermiculites in the world.

Palabora as a business must guarantee availability right across all of the different vermiculite grades.

Palabora strives for the highest quality vermiculite and that it is produced consistently and within their tight specifications.

The Company continues to have the vermiculite regularly tested by independent world renowned laboratories to certify that customers have absolute confidence in the product they are purchasing and receiving.

Having two strategic stock points, one in North America and the other in Northern Europe, guarantees customer delivery times. Coupled with their ability to send containers from South Africa to any port in the world, maintains a global coverage of 150,000 tonnes per annum.

Palabora pride themselves on a first class customer service. The ease of placing orders, makes the purchasing of Vermiculite, from the different regions around the world, an enhancement to the ‘Palabora Vermiculite package’.

Palabora Europe Ltd Sequel House, The Hart, Farnham, Surrey GU9 7HW UK Tel: +44 (0)1252 917341 Fax: +44 (0)1252 820334 email: richard.knight@palaboraeurope.co.uk

www.palaboraeurope.com

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Sharpak - Yate and Bridgewater

A neat

package With the strength and co-operation of Groupe Guillin behind it, market-leading Sharpak continues to drive a range of innovations into the packaging market

Sharpak - Yate and Bridgewater Products: Devolping and maunfacturing packaging solutions Sites: UK www.sharpinterpack.com

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ounded in 1972, family-owned company Groupe Guillin is an international specialist in developing and manufacturing packaging solutions. Through a programme of acquisitional growth the group now occupies a leading position in the global market with 18 subsidiaries spread across 11 sites and manufactures over 8.5 billion trays every year. Based in the UK,

the Yate and Bridgewater subsidiaries perfectly demonstrate the innovative and world-beating approach to business that has afforded the group such success over its history. Brought under the group’s wing in 2010, the Yate and Bridgwater sites respectively manufacture polypropelylene (PP) rigid thermapacked trays for the mushroom, poultry and ready meal industries, and PET (polyethylene terephthalate) and PET/PE (with a polyethylene laminate), for the red meat industry.

The core strengths of the companies within Groupe Guillin are very much the product of a smart and co-ordinated structure implemented across the whole network. “The group is very much focused on providing excellent service,” begins MD for Sharpak Yate and Bridgewater, Martin Taylor. “The group operates with each

individual business having its own specialism. So Yate and Bridgewater have their own markets and this gives each entity its own nuances of focus. For example, our Bridgewater facility is very highly focused on making sure that the product has a very good sealing flange because more than 90 per cent of our customers there operate modified atmosphere packaging and therefore require a reliable seal. This is not a specialism across all sites but if another company wants to get into it then we will either help them do that, or they will sell our products. Basically as a group, we can provide a one-stop-shop for our customers with highly specialised products and this allows us to service some major customers.”

Such a strategy is crucial for Sharpak and its sister companies to perform effectively in a

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Sharpak - Yate and Bridgewater

fast paced and challenging market, and this is particularly important to the group’s reputation for innovation. “All 11 sites across Europe share the same design platform,” explains Martin. “This means that we can all share our designs and ideas very quickly, which allows us to progress together at a fast pace. Each company has its own design team and in-house prototyping facilities that includes 3D digital modelling and CNC lathe machines to rout out moulds for physical samples. We have spent a lot of time recently shortening this process so we now target to get a product from initial enquiry, through the design phase and to a prototyped sample within a week. This reflects the speed of the market.”

In terms of specific innovations, Sharpak Yate and Bridgewater both present product portfolios that demonstrate a keen commitment to continuous improvement. At the forefront of recent developments is the award winning Sharpak Fortis range, which brings to market a variety of highly optimised products. Designed through a process of finite element analysis, every aspect of the tray has been optimised, resulting in a 20-30 per cent weight reduction

‘‘

We have made a lot of investment into absorption padding.

These are important to lock away liquids and maintain a clean, presentable pack for consumers

info@m-mes.com www.m-mes.com Quick - Efficient - Easy MMES (Mike Morgan Electrical Services) is an established electrical engineering and contracting company based in Bridgwater, Somerset since 1989, delivering 1st in class service to blue chip clients such as Sharpak.

Its continuing commitment to innovation and support when response is vital to Sharpak process and project management, ensures growth in its own provision, based on mutually beneficial relationship where responses are timely and a source of continuing improvement opportunities.

All aspects of electrical works are delivered to Sharpak including design, installation of power systems, process line installations, manufacture, assembly of control panels, factory and machine maintenance, inspection and testing for legislative compliance, 24/7 cover for production systems.

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and increased strength and integrity. The range has been designed in close collaboration with customers to work effectively within the most modern high speed packing lines used in food processing, and has a far reduced environmental footprint.

Another significant product, which Martin comments is gaining good traction within the

market at present, is the Vista range. Utilising innovative vacuum pack technology and a shallow tray, the materials form a tight second skin around the product to provide a number of aesthetic, quality and environmental benefits.

“We have also developed our SharpSeal range, which uses a single mono-PET material that can be recycled easily within the current post-

consumer recycling system. Continuing this trend for environmental responsibility is SharpLow, which incorporates mineral fillers in the material to reduce its petrochemical content whilst retaining its protection and strength qualities,” outlines Martin.

Other innovations are: SharpTek, which uses ground breaking anti-microbial technology to reduce the impact of cross contamination and provide reassurance to customers and consumers and SharpPlus, which uses special materials to absorb odours and increase consumer appeal. “This was originally developed for the poultry market but is becoming more popular in the meat industry, reducing the cost of customer complaints,” notes Martin. “Then for the red meat industry we have made a lot of investment into absorption padding. These are important to lock away liquids and maintain a clean, presentable pack for consumers. We made the decision that padding via the use of robots is a far superior solution to hand padding as it reduces the risk of cross contamination.

Therefore we have invested to ensure that our entire range of trays are padded by robots.”

Environmental responsibility is a key driver to

Are proud to supply Sharpak with drive and control system solutions.

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www.manufacturing-today-europe.com 63

C. Bradley Engineering Ltd Machining, Welding, fabrication & Construction

Product Speciality: RPET (Recycled Polyethylene Terephthalate) Flake and Pellet l Full audit trail and complete documentation for every delivery l Quality control checks at origin before material ships l Local warehousing for “just in time” call-off deliveries l REACH registered l Diverse supply offerings from premium high clarity options to

inexpensive B and C grades from various origin markets l Skilled team of 10 RPET supply experts l Market leading credit terms available l Serving customers in the UK and across Europe

Providing reliable, long term RPET solutions for our customers.

Bantam Materials UK Ltd 8 The Green, Richmond, London TW9 1PL, United Kingdom Tel: +44 (0)203 514 8969 www.bantamltd.com Director, Raffi Schieir MBA

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“Experienced, professional engineering company providing a reliable, high-quality service” Our services include: a Machining a Roller repairs a Product design a Coded welding a General fabrication a Aluminium welding a 24 Hour call out service a Stainless and mild steel welding a Installation & Project management a Supply of skilled labour for planned maintenance, shutdown, installation and site clearance work.

Units 3,4 & 5, Sedgemount Industrial Park, Bristol Road, Bridgewater, Somerset, TA6 4AR

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Sharpak - Yate and Bridgewater

Sharpak’s innovation strategy at present and this further entrenches the company’s leading position in a market where recyclable quality materials are critical to continued success.

Another major focus for the company at the moment is its work with customers into supply chain optimisation. “Since the recession, value has really increased in terms of being a driver for consumers,” says Martin. “This has been looking at the entire supply chain to keep the overall cost down and provide better value for the end consumer.”

innovations that we are developing and what some of our sister companies are developing in Europe are key to exploiting these. It’s a real key strength for us to be able to share these

innovations across markets, so rather than just delivering what the customer wants today, we can start focusing on what they might need tomorrow.”

Drive for innovation It is clear that operating as a supplier to the fast-paced and ever-changing consumer market throws up many challenges, but Sharpak is responding well thanks to its committed drive for innovation and the robust group structure that supports it. Groupe Guillin as a whole commits £20 million a year into investment and over the last three years Bridgewater has received £12 million to cope with demand. “A lot of this has been put into increasing the warehouse as the business grows and develops,” highlights Martin. “We have to make sure we keep our service levels up to serve the market. We are always investing into faster, better machines as well as part of our approach to continuous improvement.”

With a period of successful growth ongoing, the future for Sharpak, and indeed the Guillin group as a whole, is positive despite challenges in the supply of PP raw materials. “We want to continue growing with a focus on continued innovation and improvement,” concludes Martin.

“We have been successful so far but we see future opportunities and I think a lot of the

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Kannegiesser UK

Innovations in industrial

laundry processing

With over 60 years of know-how in industrial laundry technology, Kannegiesser prides itself on its dedication to innovation

Kannegiesser UK Ltd Products: Specialist laundry systems Sites: Hoya, Sarstedt,Vlotho, Schlema and Augsburg, Germany and Banbury, UK www.kannegiesser.co.uk

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ounded by Herbert Kannegiesser Dipl. Eng. during 1948, Kannegiesser GmbH has close to seven decades of experience in delivering laundry equipment and solutions. The business was incorporated near the town of Vlotho, Germany with just four employees and today has grown into a global venture with manufacturing bases within Hoya, Sarstedt, Vlotho, Schlema and Augsburg within Germany as well as Banbury, Oxfordshire in the UK. Within the UK Kannegiesser UK operates as the daughter company of Kannegiesser GmbH and sells and supports the entire range of Kannegiesser equipment to its UK customer base. “We can supply and install a single piece of equipment or provide multi-million pound turnkey solutions incorporating the complete range of Kannegiesser hardware,” elaborates Sales Manager Malcolm Goldie. “Our Banbury site is also a Kannegiesser

manufacturing facility producing a laundry monorail system know as ‘Supertrack’. The Supertrack monorail system is a logistic delivery system that manages the distribution of laundry to washing equipment or operator finishing stations. We also produce sorting equipment to enable different classifications of laundry to be grouped together for optimisation in the wash process – these products are sold worldwide.”

The products produced by Kannegiesser are delivered to industrial laundries that provide laundering services to a range of industries including health services, hotels and food producers that collectively wash millions of items every day. Kannegiesser manufactures a variety of industrial washing machines, ironers, tumble driers, folders and garment handling systems that all work together inside a laundry environment.

Soiled goods are delivered to the laundry to be cleaned and washed goods are then delivered

Left: Washing Technology Below left: Monorail technology, Right: Sorting Technology

back to the customers after processing. “There are thousands of industrial laundries worldwide that service this multi-billon pound industry and we provide them with the machines and solutions to service their customers,” Malcolm says. “Kannegiesser has built its business on a reputation of reliability and quality, with over 65 years of experience in this field - Kannegiesser sets the benchmark for our industry.”

As a leading laundry machine manufacturer, Kannegiesser is at the forefront of the development of innovative solutions and leadingedge equipment. It has recently pioneered a new range of folding and stacking machines that are manufactured in Germany and sold globally, while its Banbury site in the UK produces a new ergonomically designed laundry sorting system. “The new sorting arrangement has been developed to provide a more ergonomic working solution for laundry operatives responsible for sorting the laundry into classification groups,” Malcolm explains. “The ergonomic design is a modular sorting system that when compared

with our previously manufactured sorting systems and sorting systems currently offered by our competitors, provides a more operator friendly working solution to help reduce the possibility of repetitive strain injuries. Earlier sorting solutions required the operators to throw items of laundry

into sorting chutes, which in some cases required raising the arm in a throwing motion to project the item of laundry into the target chute. This action when performed over several hours could in some cases cause operator fatigue and

Vanriet Rohaco

Vanriet Rohaco specialises in the designing, manufacturing and installing automated conveyor systems.

Formed in 1990 to support the UK market, they bring together over 50 years of manufacturing experience and system design expertise.

A key part of their core business lies in the laundry sector where for the past 18 years they have enjoyed a fruitful partnership with the blue chip company Kannegiesser.

With Kannegiesser’s expert knowledge in the laundry industry and Vanriet Rohaco’s expect knowledge in the conveyor industry; they complement each other and together have completed many large and prestigious projects for laundries around the world.

Vanriet’s head office situated in Tamworth and Kannegiesser UK head office in Banbury, they can easily communicate on project achieving top class results with beneficial reward for customers and both companies alike.

Vanriet Rohaco’s Managing Director Theo van Riet says: “The partnership with Kanniegesser is very important to us and I am sure both companies will play a large part in the industry and will move forward in to the future together.”

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Kannegiesser UK Ergonomic Sorting Solutions

repetitive strain. To negate the need to throw an item of laundry into a sorting chute, we have developed this new sorting solution that only requires the operator to deposit an item of laundry into a sorting chute with a simple lift and drop action that does not require the operator to raise an arm into a throwing position.”

With an ever-growing awareness of unsatisfactory working conditions, ergonomic

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consideration is becoming even more important in the design of new hardware. Therefore the ergonomic sorting solution has been welcomed by customers that have the wellbeing of their operators to consider. As such Kannegiesser UK manages a research and development department comprising of four dedicated designers that are responsible for bringing new monorail hardware solutions to market from

conceptual design and delivery to its customer base. All design projects embarked upon are managed within strict guidelines that involve all disciplines within the organisation, comprised of sales; manufacturing; and installation, service and support departments, that are all involved in the development of new products.

In an ever-volatile global economy, innovation is key to ensuring that businesses remain resilient and profitable. Kannegiesser works closely with its clients to understand the needs of the market and to focus on the development of its products to provide the best solutions. “Our customers are constantly striving to achieve lower production costs to gain a competitive edge against their competitors,” Malcolm explains.

“The biggest gain is reduced labour costs, so any mechanical hardware that can be introduced into an operation that reduces headcount is a major attraction to our customers. Kannegiesser manufacture a range of labour saving hardware solutions, and our objectives are to continually improve and develop our products to achieve even more labour saving solutions.”

Further to the development of labour saving products, Kannegiesser is committed to the development of strong relationships with its clients, which it maintains through a private exhibition held by Kannegiesser GmbH every two years. This allows the company to showcase its new hardware, while giving clients the opportunity to meet with Kannegiesser personnel and industry peers to discuss market conditions and requirements. These events support the company as it continues to grow and moving forward it will look to emerging markets such as China and Russia as well as expanding its market share in established market locations.

“Our strategy to achieve this has been the same for many years,” Malcolm concludes. “That is to continue development of innovative designs that help to keep us at the forefront of our industry.”

WALDRICH COBURG

Next generation

machines With roots dating back as far as February 1920, the history of WALDRICH COBURG began with the establishment of the company engaged in the repair of machine tools

WALDRICH COBURG GmbH Products: Vertical milling, horizontal milling, vertical turning machines and grinding machines Sites: Germany, the US, Russia and China www.waldrich-coburg.de

I

n 1926 the company acquired and relocated to a building in Hahnweg, which today is the heart of WALDRICH COBURG, namely, the design, production and innovation of portal type machining centres for milling, turning, drilling, boring and grinding in Germany.

Over the course of 95 years the business has continued to grow further developing into an international company offering first line service and the production of vertical milling, horizontal milling, vertical turning machines and grinding machines.

“Nowadays we offer the most comprehensive product range of large, heavy duty machine tools in the world, with workpiece dimensions starting at 2m by 1.5m by 4m and upwards,” explains Director of Sales, Matthias Fleischer. “The world’s largest and heaviest machine components are machined mostly on WALDRICH COBURG machine tools, parts weights can reach 500 metric tons! Especially our PowerTec and MasterTec machines set global standards in productivity, accuracy and durability for our customers in the power, diesel engine and heavy engineering industries.”The largest machines ‘Made in Coburg’ can weigh 1500 metric tons. Also the company’s WayGrind machines have gained an unbeaten reputation at machine tool producers on all continents. Especially Japanese makers like Okuma, Mazak and others are favouring these masterpieces of German engineering coming from this little town in northern Bavaria.

During 2005 Beijing No.1 bought the company

and invested a considerable amount of capital in its manufacturing facility in Coburg, where it continues to produce its line of machines. Over a period of ten years €60 million was invested in new factory buildings and machines, offices, repairs and common rooms.The development further strengthened the trust of the company’s customers, who recognise WALDRICH COBURG as a reliable, strong partner that embodies a long-term perspective. During this time the company enjoyed a great period of success, doubling its sales and increasing its workforce from 500 to 800 employees.Today WALDRICH COBURG operates as a strong global player that maintains a presence within Germany, the US, Russia and China.There the company has provided solutions to many of industry’s leading names including ALSTOM, Caterpillar, Siemens,Volkswagen, MAN, Wärtsilä, China Shipbuilders CSSC and CSIC, Dongfang Turbine, Mitsubishi, Hyundai, Larsen&Toubro and BHEL to name a few.

One of the most recent developments for WALDRICH COBURG was the company’s announcement in March 2015 that it had established an on-site service base within Beijing to enable it to better service the 135 WALDRICH COBURG machines in China. Currently ten employees, including specialists from Germany, support WALDRICH COBURG customers and values in China. Its long-term approach is to establish a service platform for the entire Asian region and to deepen its cultural understanding and awareness

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Ortlieb Praezisionssysteme GmbH & Co. KG Dettinger Str. 129 73230 Kirchheim / Teck, Germany Tel: +49 (0) 7021 9469-0 Fax: +49 (0) 7021 9469-51 info@ortlieb.net

www.ortlieb.net

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WALDRICH COBURG BLIS

BLIS belongs to the midsize linear motion manufacturers in Germany and is focusing on heavy-duty precision linear motion components for large machine tools. The product range covers ball screws, trapezoidal threads and satellite roller screws.

BLIS components are designed to customer needs and customer applications. BLIS is serving leading machine tool manufacturers on a global basis. BLIS can produce ball screws and trapezoidal threads up to 200mm diameter and 20,000mm length. A maximum dynamic load of 6,000KN can be achieved.

Ortlieb

Maximum performance – innovation, quality and precision For more than 100 years Ortlieb has been a precision company and defines itself as a customer-oriented partner for economic and precise clamping and drive solutions. You benefit from its synergy effects: more innovation, increased dynamics and flexibility due to integrated organisation and manufacturing structures. This means that Ortlieb is scooping from a wide product spectrum of standard solutions. Furthermore, customised solutions are offered fast and of high quality.

The company can look back on many years of partnership with Waldrich Coburg. In co-operation with Waldrich Coburg’s engineers, it develops customised Automatic Tool Clamping Systems, Type SK and HSK: they allow much higher clamping force than the recommended minimum clamping force according to the standards and convince with their maintenance-free systems through ceramic on the functional surface for shorter clamping application and faster tool change.

The Ortlieb Präzisionssysteme GmbH & Co. KG company, together with the 2E Mechatronic GmbH & Co. KG company, belongs to the Narr Group, an internationally operating technology supplier with about 170 employees.

of its customers in the region. “We have to comply with the requirements of the market, because the conditions have changed over time. Customers expect fast on-site support and are no longer willing to accept financial losses due to long machine downtimes,” elaborates CEO Hubert Becker.

“Another important aspect for us is the immediate integration of Chinese managers in the service business to increase customer confidence and to intensify the business relationship.”

Following the significant growth of the business and a consistent history of investment WALDRICH COBURG is able to continue to develop and provide exciting new machine products to market.

During November 2015 it plans to make the official launch of its TAURUS portal milling machine.The TAURUS was premiered at the AMB international exhibition for metalworking during September 2014 in Stuttgart.TAURUS was developed in response

to increasing demand for machines in those sizes and represents WALDRICH COBURG’s best priceperformance machine tool of all time. “Like other system manufacturers, we have a core business,” Hubert explains. “With this new development, we aim to make ourselves even more future-orientated.

We see a lucrative market, which we are sure to win over with our new product.”

WALDRICH COBURG offers a high level of customer orientation with the TAURUS, with three different types of control system available.

The control sets provided by Siemens, Heidenhain and Fanuc are well established in the global market and can be selected according to the customer’s requirement. WALDRICH COBURG therefore offers customers the control they want to use on an individual basis.The machines encompass table sizes of 2.000mm x 4.000mm and 2.500mm x 5.000mm and offers a wide variety of functions, such as the CNC-C axis, integrated in the RAM, tool and spindle unit changer, etc.The customer can choose different spindle units to best suit its machining requirements.

The success of TAURUS relies on the optimisation of the operational processes followed by efficient production throughput with short installation and commissioning times. “As part of our cost management programme we will be building machines in small batches,” reveals Matthias. “By shortening the throughput times, we can produce up to 20 TAURUS machines per year.”

“Our goal is to initially produce ten machines per year, which is consistent with the competitor figures available and we believe this market potential is extremely realistic,” Matthias adds. “The responsible colleagues at WALDRICH COBURG are certain that the new production processes with the relevant test and evaluation fields will guarantee a high output for the TAURUS milling machine.”

Even prior to its official launch,TAURUS milling machines are generating significant market interest.

The first two TAURUS machines will be operated in Germany, while a further unit is destined to be delivered to an Indian customer. Indeed TAURUS is already set to make a decided impact within a number of applications. WALDRICH COBURG’s client located in North-Rhine Westphalia is a specialist for forming technology with innovative solutions for the die and mould industry, which represents an ideal fit for the new series of machines.The second German customer from Lower-Saxonie produces high accuracy components for production plants. Long-term precision and short processing times achievable on the TAURUS were

the key arguments of these customers to decide on WALDRICH COBURG. Furthermore the excellent support in application engineering including time studies and operation simulations were convincing.

The company of the Indian buyer is one of the biggest suppliers of locomotive and railway equipment. Its facilities are located in the northern part of India (Haryana, Punjab and Chandigarh) with a covered space of 30,000 square metres. Due to its state-of-the-art production site, the well-equipped metallurgical laboratories and its high-quality process analyses, it is among the world-leading companies in this field of operation.

The initial customers of the new TAURUS machines represent a varied group of industry sectors, reflecting the wide range of applications for the system. Regardless of its use within the mould and die, general machine or diesel engine production industries,TAURUS delivers the perfect balance of design and strength.The first TAURUS components will be shown during the EMO trade fair in Milan during October 2015. “TAURUS is just what we wanted, a high-quality universal machine for all industries that provides the best possible price-milling ratio,” Hubert says. “In these days of high competition the machine is a useful complement of our product portfolio - the order receipts show this and encourage us!”

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Rexnord FlatTop

Moving As a global leader in conveying components manufacture, Rexnord FlatTop is committed to driving efficiencies through its customers’ facilities with a focused and clearly defined innovation strategy

Rexnord FlatTop Products: Manufactures conveyer chain components for various industries Sites: HQ: Wisconsin, US www.rexnordflattop.com

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forward H eadquartered in Wisconsin, Rexnord is a global leader in delivering high quality products under two strategic platforms: process and motion control, and water management. Employing around 8000 people around the world and with over 120 years of experience, Rexnord has established for itself a robust reputation for delivering innovative, high quality and durable products. Through a programme of continuous improvement across product development and manufacturing processes, the company aims to consistently create superior value for its customers, shareholders and associates.

Rexnord’s FlatTop division designs and manufactures standard and bespoke conveyor systems for the food and beverage, industrial and automotive markets. The company supplies OEMs, end-users and a network of distribution partners around the world and is currently experiencing significant success as its core markets grow. With global population rising and a middle class expanding in many developing

countries, the global food and beverage industry is currently experiencing a period of positive growth, as to is the automotive industry.

“We listen to our customers and their voice is number one,” begins Rexnord VP and Business Manager for FlatTop, Rick van den Berg. “We are also very capable of problem solving. With such a vast bank of expertise and experience we have a reputation for never walking away from an issue.” Rexnord FlatTop places itself firmly in the driving seat of the conveyors industry by delivering the majority of significant innovations and retaining technology leadership across the world. Innovation focuses revolve around four main drivers: safety, productivity, energy saving and water reduction. In a push to deliver this to the market for the last three years Rexnord FlatTop has been developing its Engineered Sustainability product programme.

“Engineered Sustainability is a product programme focused on developing and launching solutions around these four central topics,” explains Rick. “It is a product programme that enables our customers to utilise durable

conveyor systems with components that guarantee optimum product handling solutions, without compromising the ability to meet our customer’s targets of safety improvements, productivity optimisation, energy savings, product protection and water minimisation.” By working closely with its customers Rexnord FlatTop deploys its skilled engineers to help obtain low Total Cost of Ownership (TCO), resulting in cost savings by improving the overall operational processes.

Currently sitting amongst the Engineered Sustainability product portfolio is the ZeroGap Multi-flex Chain, which has a patented top plate design to allow for tight side-flexing with no gap opening on the surface. This unique design enhances product performance and results in less tippage, reduced debris trapping and improved safety. Accompanying this, amongst many others, is the 661 Series Chain which offers improved product handling with smooth running conveyors, optimal bottle stability and low noise levels. A 25 per cent reduction in chain weight also means lower headshaft tension. In October 2015, Rexnord FlatTop will be attending the annual Brau Beviale exhibition in Germany to showcase its Engineered Sustainability product range and will be launching its new generation of low backline-pressure solutions designed to help increase safety, offer optimum product protection and reduce noise levels in packaging conveying.

Innovation is at the heart of Rexnord FlatTop being able to deliver these industry-leading solutions to the market. “We offer industry standard products, which are designed around the latest industry needs. This is a big portfolio of solutions, which are available off the shelf for low, medium and high speed bottling and filling,” highlights Rick. “Beside this, especially for OEMs, we are able to utilise and offer customisation to customers to optimise products for specific installations. We have continued our innovation drive in terms of materials as well and have just launched a hybrid material technology by combining engineered plastics with metals.”

To facilitate this level of continuous improvement across the global organisation, Rexnord employs a business operating system, which derives itself from Toyota’s renowned business system. Named the Rexnord Business System (RBS), it ensures that all manufacturing plants around the world are focused on the same strategy. In essence, RBS creates a scalable, process-based framework that focuses on driving superior customer satisfaction and financial results by targeting world-class operating performance throughout all aspects

of the business. “In terms of capability, we have metal processing, injection moulding, machining, extrusion, testing, assembly and shipping all done in-house,” outlines Rick. “We also do all of our research and development in-house, which is supplemented by working closely with our

global suppliers of resins, metals and technology to ensure we are driving the industry forward in the best way possible.

“As for the future”, Rick continues: “Over the next year we will be focusing heavily on expanding our Engineered Sustainability offer for

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Rexnord FlatTop primary and secondary packaging applications.

We will also be looking to further develp our product offering for the automotive industry. In the longer term, Rexnord is planning to take a leading position in providing and demonstrating manufacturing efficiency by continuing to offer the most reliable and durable products in the industry. “Last but not least, we continue to ensure that we are easy to do business with.�

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Salop Design and Engineering

A collaborative

approach

Not only does Salop Design and Engineering demonstrate a strong manufacturing capability and reflexive approach to the market, but also an exemplary attitude to the wider industry and local economy

Salop Design and Engineering Ltd Products: Manufactures metal pressings and assemblies Sites: Shrewsbury, Shropshire, UK

F

ounded in 1960, Shropshire-based Salop Design and Engineering Ltd has grown from a design agency into a leading UK manufacturer of pressings and assemblies for a range of industrial applications. Mostly serving the automotive, white and yellow goods sectors, the company predominantly operates in the UK but currently exports 20 per cent of its production to Europe and the US. “Today we have mechanical, progression, hydraulic and transfer presses up to 1000 tonnes,” explains Commercial Director, Christopher Greenough. “We also have two state-of-the-art powder coating lines on site, and combined with our own haulage firm we are truly a one-stop-shop for all pressing and coating needs.”

With the automotive TS16949 quality standard in place Salop has developed a robust range

of processes to monitor and maintain delivery, quality and cost to its customers. “We project manage to the customers’ requirements and expectations,” says Chris. “We really pride ourselves on reacting to customer needs and being fully involved in the supply chain. We have a good name within the industry for metal presswork and have achieved remarkable results in growing the powder coating side over the last three years.” As a tier two supplier Salop deals with all of the major UK-based automotive facilities and Germany represents its biggest market outside of the UK. “We have bespoke, state-of-the-art hydraulic presses that can take customer tool concerns and provide real production options,” outlines Chris. “Supplementing this is a full project team that involves top management to make sure customer expectations are fully met.” As a result,

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Salop possesses the ability to process material from 0.4mm to 20mm in-house, as well as a deep draw capability.

With such a comprehensive technical capability behind it, the company has been able to offer a leading, specialist service to the market. Of note, major contracts in the company’s portfolio include the processing of all rear muffler boxes

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for the Rover 75 car produced in the UK until 2005, and all BMW Mini One and Cooper S rear muffler boxes up until production moved out of the UK in 2006. More currently Chris highlights: “We have taken on a customer’s concern about a fuel tank from their existing supplier. In 2004, they moved the tooling to Salop and within two weeks, we had turned the process around to give

Salop Design and Engineering

them a production process that worked.”

Despite reaching its leading position in the UK’s automotive industry, Salop still felt the full force of the economic recession. “In 2009 when the recession hit the UK automotive industry we relied on that industry for 90 per cent of the company’s turnover,” notes Chris. “This had a major impact on us, which meant that we had to make redundancies and revisit the site’s business model. As a result we invested into our first powder coating line the fourth quarter of 2012 in order to dilute the reliance we had on automotive presswork. Since then the powder coating customer base has grown and in 2015 a second line was added.”

An investment of £1.5 million was put into this diversification and is focused heavily on

high-end technology. The state-of-the-art facilities now include seven-minute quick colour change booths and 97 per cent recycled powder facility.

Such is the rapid success of the turnaround that by the end of 2015, Salop will see a 50/50 split in revenue between automotive and nonautomotive industries. “This diversification has not only helped to secure the current workforce, but has also really allowed us to grow,” adds Chris. “The predicted turnover for this year is on target and set to be a record year for the company.”

However, it is not just into its own manufacturing processes that Salop is investing heavily as the economy emerges out of a recession. It is currently in the middle of a £250,000 investment into renovating and kitting

out a training centre for manufacturing. “The centre will be run by In-Comm Training and Business Services and branded as ‘In-Comm Training Academy Shropshire’,” explains Chris.

“When it opens in 2015, it will allow employers in Shropshire to help their apprentices gain the real core skills of engineering. It is set to become a hub for manufacturing businesses to upskill their current workforce, and start their apprentices on the road to adding value to their business.”

This outward commitment to serving the wider industry is deeply ingrained in Salop’s philosophy as Chris himself is also the President of ‘Made in the Midlands’, an organisation promoting the local area’s manufacturing expertise. Combined with Salop’s attitude to continuous training and upskilling within its existing workforce, and an ongoing apprenticeship scheme, it is no surprise that the company became the recipient of the Manufacturing Excellence award at the 2015 Shropshire Chamber Business awards for its work with the local community and young people, and its commitment to the region.

“Since the recession in 2009, we have built the company back up slowly and methodically,” concludes Chris. “Whilst there are certainly still challenges ahead as customer demands and expectations are ever increasing, I see a great amount of opportunity for those manufacturing companies that have stayed around, and have become leaner and keener to make the UK a go-to place for manufacturing.” With this in mind, the future for Salop is very much driven by growth, with a target to increase turnover and exports by 40 per cent within the next five years by attracting new customers and remaining committed to its existing customers and core values.

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Hi-Force The Hi-Force UK manufacturing facilities in Daventry, England

In

demand

Hi-Force is the fastest growing hydraulic tools manufacturer in the world today

Hi-Force Ltd Products: High pressure hydraulic tools Sites: UK, UAE, Azerbaijan, Italy, Malaysia, the Netherlands, South Africa www.hi-force.com

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O

riginally introduced to the market in the late 1980s, the Hi-Force brand enjoyed two decades of moderate success before a management buyout and restructure in the early 2000s which resulted in the Brown family taking control of the business in 2006. “It was at this point in the company’s history that I relocated back to the UK as Group Managing Director, following a highly successful 14 year stint of setting up and managing Hi-Force’s Middle East operations in Dubai, UAE,” says Managing Director Kevin Brown.

Since then, the company has witnessed ongoing success and prosperity, with almost 190 per cent growth and a tripled workforce since 2009. Key to this incredible growth is Hi-Force’s strategic decision to progress into in-house manufacturing, which meant Hi-Force ended many years of dependency on sub-contractors.

In line with this development, Hi-Force relocated to a brand new, state-of-the-art facility, in 2010, which is in close proximity to its earlier, much smaller, facilities in Daventry, UK. The new site, at over three times the size of the previous facility, has enabled the firm to combine all

manufacturing and production facilities under one roof, alongside its sales, marketing, assembly, training, logistics and administration departments.

“We manufacture our products from within our headquarters and manufacturing facilities, in Daventry, Northamptonshire, where you can see the complete manufacturing process, from raw material being delivered by our steel and aluminium stock holders, to finished, boxed product being shipped out. Having everything on one huge site, spanning over 120,000 square feet, creates huge efficiency gains. For the business, plus allows our customers to see first-hand exactly how the tools, they buy and use, are manufactured, assembled, tested & certified, finished, packed and despatched,” confirms Kevin.

“To further support our business and our customers, 80 per cent of which is exported outside of the UK, we have established Regional Offices & Distribution Centres in Europe, the Middle East, Far East & Africa, with plans in place to open a Regional Office in the Americas, in 2016. We also receive fantastic support from over 100 strategically placed, authorised and appointed distributors, in over 80 countries, which

Top: A batch of TWH54N Hydraulic Wrench Drive Cylinders being assembled Bottom: Part of the recently shipped huge order for Riyadh Metro in Saudi Arabia, delivered within 14 weeks of order

provide the key link between Hi-Force and end users of our products,” he adds.

Used in a wide range of industries, including oil and gas, refinery and petrochemical, power generation, mining, railways construction, steel and aluminium plants, aerospace, ship building and ship repair, as well as sugar and paper mills, Hi-Force’s hydraulic tools can be relied upon to deliver optimum quality to the most challenging or hazardous of projects. Key to this reliability is the company’s commitment to research and development, which also ensures Hi-Force remains at the forefront of high pressure, hydraulic tool technology. “In the last two years we have invested hundreds of thousands of pounds in expanding our technical design and engineering team. We now have five full time design engineers compared to just two at the beginning of 2014, all dedicated to improving product designs and introducing innovative new products to our global customer market,” says Kevin. “We also use the very latest design software and currently have several new products in the pipeline that are due for launch in the coming months.”

Although it is too early to discuss these upcoming innovations, Hi-Force has recently launched a new range of 700 Bar, maximum working pressure, electric driven hydraulic torque wrench pumps; available with a choice of electric

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Hi-Force

or air driven motor, the pumps are used with the company’s hydraulic torque wenches. “The innovation comes primarily from the three speed design and operation of these pumps, compared to commonly used two speed versions that are offered by our competitors. Not only does the three speed design improve speed of performance, which thus saves operators valuable time, it also enabled Hi-Force to design and manufacture this innovative new product in-house, rather than using sub-contracted and proprietary brand components,” highlights Kevin.

He continues: “We achieved three major successes here: a better more efficient and lighter weight pump, with the added success of a lower manufacturing cost. Previously over 90 per cent of the component parts of our pumps were outsourced; now over 50 per cent of the components are manufactured in-house. Sales during the first half of 2015 have far exceeded our

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expectations and our in-house design engineering team are justifiably proud of the success of this project.”

Indeed, playing an integral role in Hi-Force’s accomplishments are its highly motivated and hardworking employees, who are all dedicated to supporting the Brown family in achieving all of its core objectives. “I believe our core strengths to be our people and our high quality products, both of which are absolutely vital to ensure we continue to grow and prosper,” confirms Kevin.

“The last ten years have been absolutely amazing for the business, as it has grown from being a small tools supplier to an innovative and market leading manufacturing business.”

As increasingly demanding industries call for higher quality products and Hi-Force remains in demand, it has made massive investments in machinery to ensure customer needs are met or

exceeded. “In 2014 we spent over £1 million on three new DMG Mori CNC machines and in 2015 to date over £300,000 has been spent on four Haas CNC machines and associated equipment.

In fact, the purchase of a huge new DMG Mori SL603 lathe machine last year proved pivotal in us recently executing a huge order for the Riyadh Metro Project in Saudi Arabia. The order was in excess of $2 million and, from date of order to date of despatch, was completed in less than 14 weeks. Five 40 ft containers full of hydraulic jacking equipment, manufactured in Daventry, are now en-route to Riyadh, Saudi Arabia! This is a very proud achievement for our business and our employees; we could never have met our customers’ demanding delivery schedule, without having our own in-house manufacturing capability,” enthuses Kevin.

Despite these major successes, Hi-Force has no plans to rest and enjoy the fruits of its labour and instead is looking to further expand in the near future before purchasing more manufacturing machines in 2016. “Whilst we are delighted with the growth we have achieved, since relocating to our current facilities in 2010, the next 12 months will see us re-evaluate our complete manufacturing processes, to better streamline our activities, to further increase efficiency and achieve a key element of our next five year plan,” says Kevin. “This is split into four key areas: gain market share, increase brand awareness, best in class ROI and cash flow and to be a respected employer. We are now well into the implementation phase, through a wide variety of initiatives to ensure we achieve our ‘must win’ battles and fully realise our vision,” he concludes.

Chemigraphic Conformal coating machine in action

Best of

British

Through continuous investment and a pride in delivering a UK level of quality to its customers, Chemigraphic Ltd is at the forefront of electromechanical integration and product support for OEMs

Chemgraphic Ltd Products: PCB assembly, system integration, product lifecycle support Sites: Sussex, UK www.chemigraphic.co.uk

A

t the forefront of electronics services provision, Sussex based electromechanical integrator Chemigraphic Ltd is a renowned specialist in the design, development and manufacture of PCB assembly, box build and system integration for industries including communications, advanced simulation, medical technology and defence and security. Able to offer a solution that supports an OEM’s complete product lifecycle from a basic prototype and NPI service through to a repair, spares and warranty management programme, Chemigraphic is able to meet its customers’ precise needs and specifications. Today operating out of a state-of-the-art 50,000 square foot factory, the company is proud to deliver the best of British when it comes to premium quality,

fit-for-purpose products; a pride that stems from more than four decades of experience and expertise.

Elaborating on Chemigraphic’s history, Stephen Perkins, CEO of Chemigraphic Ltd begins: “The company originally began as a family business and traded profitably over the years under family ownership until 2010 when the owners decided to retire and sold the business. New investors and a new management team was brought in and we have been running the business since 2010 under that guise. Although we have continued to maintain the family’s legacy, we have also invested in a more functional and formal management structure to ensure we can support existing customer need and develop new business as well. Alongside this development, we have invested more than £3

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Chemigraphic Below and bottom left: Integrating circuitry into mechanical products

Charcroft Electronics

The relationship between a component distributor and an EMS provider is typically one of straight-forward order fulfillment. There are, however, many situations in which a distributor’s specialist knowledge can provide a much more comprehensive level of support.

For example, as a specialist component distributor Charcroft Electronics’ expertise and understanding of the OEM market can be used to identify “better than” alternatives to existing components. On a technical level, these alternatives can offer more functions and improved performance to support a process of continuous improvement for new designs or for design upgrades. A commercial alternative could provide a second-source to minimise the risk of future delivery issues.

Specialist knowledge can be accessed through online chat on the Charcroft website, from a field-based specialist in passive, electromechanical, optoelectronic or power components, or via a telephone Help Desk. However it is accessed, this expertise offers OEMs and EMS providers considerably more than simple order fulfillment.

Populated circuit board

million in the factory, both in terms of expanding capacity and capability, particularly with regards to automation.”

By acknowledging that investment is a crucial part of staying ahead of the game, the ISO 9001, ISO 13485, ISO 14001 and ISO 22301 accredited Chemigraphic is not only capable of delivering highly competitive electronic product build outsourcing services to OEMs, both in the UK and abroad, but can also deliver a turnkey service that includes shipping to the OEM’s end customer if that is a solution that the OEM wants Chemigraphic to deliver. “Some companies in our sector specialise in populating printer circuit boards with components and that is also part of

the service we offer; in fact, it is an area we have invested in heavily to ensure we are doing this as efficiently as possible. However, we have also invested in being able to offer the full box build, rack assembly and system integration services to our customers, which means we can take the populated circuit board and start wiring it into harnesses, chassis or racks; for some companies we build the PCB into the end product on behalf of the OEM customer. For example, we have a customer that does no manufacturing whatsoever and instead focuses on R&D, product marketing and external sales whilst outsourcing the manufacturing and product support operations to Chemigraphic.”

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Surface mount line in action

Chemigraphic

NCAB

Chemigraphic and NCAB have a strong proven track record of achieving and growing a sustainable, successful business relationship together.

Chemigraphic are a long, established loyal customer to NCAB, a relationship which stems back to our infancy 5½ years ago. NCAB have established themselves within Chemigraphic’s supply base as a preferred and valuable supply partner who have supported their customer needs through some challenging and demanding times.

We are delighted to have shared and celebrated success and growth together across all business sectors.

Below: Selective solder in action

In more detail, Chemigraphic split its investment into two areas, capacity and automation, as Stephen notes: “Following investment, we now have a 50,000 square foot capacity in the UK. Meanwhile, in terms of automation, I think we are one of the first UK, if not European, based electromechanical integrators to invest in an intelligent storage management system which automates the kitting process for our surface mount lines.”

By automating this process the company is able to feed its machines with materials faster and has increased the speed and efficiency for changeovers. “The stock management, selection and material placing processes are now entirely automated which means we can compete effectively with eastern European or far eastern competitors for this element of our offer.”

This forward thinking approach to automation and expanding capacity has served Chemigraphic well, with the company enjoying an average of ten per cent sales growth year-on-year since 2010. In addition to these vital investments, Chemigraphic maintains a competitive edge thanks to its 150 strong team of operators and engineers who can offer customers the best value through excellence in electronic design for manufacture and procurement solutions. Indeed, the range of engineers, software specialists and technicians within Chemigraphic are trained to the latest revision of IPC-A-610 and IPC/ WHMA-A-620, utilising J.STD-001, meaning

Exception PCB Professional Printed Circuit Board Design, Manufacturing, Procurement and Supply Chain Risk Management

From fast turn manufacture of highly complex PCB’s in the UK to high volume supply from Asia, eXception PCB Solutions provides a full range of PCB requirements. As one of Europe’s leading electronics outsourcing providers, exception’s combination of ‘Best in Class’ manufacturing capability and Global Supply Chain Management expertise offers lowest total cost of ownership for our customers.

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Chemigraphic

Chemgraphic’s offices in Sussex

Integrating circuitry into mechanical products

they have the skills and experience to meet any specialist request, which will be delivered on budget and to schedule. Working in close co-operation with clients throughout the development process, the company ensures total customer satisfaction.

Clearly not a company to rest on its laurels, Chemigraphic has further strengthened its capabilities with the introduction of two types of services recently. “The first service is selective solder, which means we are automating what is currently a manual task using software to direct the soldering process; this development has already enhanced our service and quality levels. Alongside that development, we have brought conformal coating in-house, which is a form of protection that is suitable for customers who want their products to go into rugged environments. It is a fully automated solution that again uses software to automate the coating process; it enables a faster flow through of volume for the customer and maintains high levels of quality in that area of the factory.”

Following five years of major developments, the future looks increasingly positive for Chemigraphic as it seeks new opportunities to further advance its offer to OEMs and enhance its capabilities in order to maintain a competitive edge. “Although our strategy is centred around meeting the current and future needs of our existing customer base, we are also looking to acquire similar UK based businesses within our sector. There are quite a few businesses out there that aren’t at the same scale as Chemigraphic

but may have strong customer relationships or a product that we find interesting and could benefit from the investments that we have made in our own processes over the last five years.

There are a lot of exciting things happening within this sector as products require electronic

control systems more than ever and being able to provide and build the required technology or find innovative solutions to complex problems within the business-to-business market, and from a UK base, is a truly exciting place to be,” concludes Stephen.

CC Electronics

CC Electronics has supported the success of Chemigraphic, over the last 10 years. As a leading British manufacturer of printed circuit boards (PCBs), CC Electronics has been able to satisfy Chemigraphic’s requirement for prototype and production volumes across all sectors of their business. Quality, speed and flexibility are the key pillars of the CC Electronics’ supply model. Complex multilayers are regularly manufactured in 24 hours. Also, in an attempt to offer a solution to all their PCB needs, CC Electronics has developed a fresh, low risk approach to offshore supply. Being a manufacturer, this makes it easy for it to assure the quality of the offshore product through microsectional and XRF analysis.

So, local manufacture… global sourcing.

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Johnston Sweepers

A clear

path

A commitment to innovation, customer service and environmental responsibility is central to Johnston Sweepers as the company looks forward to a successful future

Johnston Sweepers Products: Manufactures road sweepers for street cleaning Sites: Dorking, Surrey, UK www.johnstonsweepers.com

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ounded in 1904 as Johnston Brothers, a company that held a license to make road surfaces out of crushed stone, Johnston Sweepers is now the worldleading manufacturer of street cleaners. “Back when the company was formed the brothers started to build the business around road laying.

As the company developed they bought some quarries and in 1924 they founded Johnston Engineering in Dorking to make equipment like tar boilers, trenching equipment, snow ploughs and so on. The pattern was that everything they made could be sold to a municipal,” explains David Bishop, Operations Director of Johnston Sweepers.

In 1958, the company developed the first ever vacuum sweeper, which entered the market in 1960 and which has remained the template for sweeper design ever since.

True to its deeply entrenched roots as a British manufacturer, Johnston’s business today centres very much on the values of domestic manufacturing and supply chain management. “Up to 75 per cent of our production spend goes to UK suppliers,” says David. “In terms of our own processes we are a fully integrated manufacturer, producing our products from a single flat sheet of

steel all the way through to a full vehicle. In 2008 when the recession hit, our market all but disappeared for a while.

However, rather than moving abroad to cheaper countries we decided to invest in developing our manufacturing facilities in the UK where we have always been based and this has worked out really well for us.”

At the heart of Johnston’s progression to the present day is its focus on innovation and product development. In July 2015, the company officially launched one of its latest products, the C401 compact, at the RWM Show. “This is one of our principal products at the moment,” explains Graham Howlett, UK Sales Manager. “Its unique feature is its front, forward-facing brush arms, which are better suited for cleaning hammer heads and

Linde Hydraulics

Linde Hydraulics have been supplying Johnston Sweepers with the hydrostatic drive system and steer axles for their compact sweepers since the start of production in 1989.

Over this period we have jointly developed the transmission to its current level. This offers the latest electronic controlled hydrostatic system using our HPV high pressure pump fitted with the latest safety control which is integrated into the vehicle management system.

In addition, together we have developed a weekly supply system in re-usable stillages, supplying their full requirement in two working days from receipt of the order being placed. Also our supply has developed from components to complete subassembled products to allow them to be built directly into their machines, saving time and space within the assembly line.

Today we have to work with our customers to develop the complete system.

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Johnston Sweepers

IMI Precision Engineering

IMI Precision Engineering and Johnston Sweepers are set to begin the next chapter in a working relationship that stretches over 20 years. IMI Precision Engineering has been chosen to supply pneumatic cylinders and control systems to co-ordinate positioning, levelling and surface contact pressure on the sweeping and vacuum arms, for the latest generation of road sweeper vehicles.

The control panels and actuators are custom designed to meet Johnston’s needs for safety and reliability within a challenging operating environment. Production of the actuators and assembly of the control equipment is fulfilled from dedicated manufacturing cells at IMI Precision Engineering in Staffordshire.

Motherson Sumi Systems

Motherson Sumi Systems Ltd. (MSSL) is a diversified auto components manufacturer with a presence in 25 countries across six continents. The company is a full system solutions provider for a wide range of products and a leading supplier of wiring harnesses, rearview mirrors and plastic modules and components.

MSSL GB Ltd., a subsidiary of Motherson Sumi Systems Limited, supplies Electrical Distribution Systems to the outdoor sweeping machinery of Johnston Sweeper Limited. It is proud to be associated with Johnston Sweeper Limited, one of its most valued customers in Europe.

have greater access in tight turning circles. We have introduced a fourwheel steer feature as standard as well, which allows for greater manoeuvrability and it has a range of features such as a larger water tank and larger hopper capacity for longer on-station time, so we think this C401 has a lot to help it stand out in the market.”

Launched to European dealers in June 2015, the C401 is Johnston’s cleanest, most efficient and most manoeuvrable midsized sweeper yet. “It predecessor was popular in certain locations but this new one, which offers a larger payload and smaller turning circles, gives us greater access to a larger customer base,” adds Graham. In addition to this, the company has also been working closely with its North American customers to develop the new ES351. “This is a new mechanical sweeper,” highlights David. “Whilst our vacuum sweepers do have very good market penetration in America, it remains a very traditional market and over half of sales are still mechanical sweepers. Therefore, our R&D department has had to design to compete in that market, which we have done in cooperation with our customers.” In addition to its new products, Johnston has also demonstrated its focus on continuous development with upgrades to its Euro 6 C201 Compact and V-Range truck mounted sweeper products.

“R&D is central to the future in developing further product segments, continuing to grow market share in new territories and continuing research to reduce emissions,” outlines David commenting on the importance of innovation

at Johnston. Graham continues: “We listen, we engineer, we deliver. This is the slogan that really sums up our organisation and how we talk to our customers.”

One particular focus for the company’s R&D is into environmental responsibility, for which it has recently received two significant awards: the Green Apple award and the Scottish Supplier Excellence award. “Taken together these reflect the broad range of activities in which we consider environmental issues for the materials that we buy, the products we sell and the processes that we use to convert these materials into a finished product,” says David. “The Green Apple award is an architectural award for our new manufacturing plant in Surrey, which also achieved an ‘Excellent’ BREEAM rating for the sustainability of the building.” The new plant was opened in 2014 after a £11.4 million investment to consolidate the three UK sites that previously existed.

“We achieved this rating in a number of ways,” continues David. “Firstly, there are no light switches in the factory. Instead, the lights control themselves according to natural light and activity in the factory. We have also installed photovoltaic cells on the roof, which generate 42,000kW hours of energy per annum, and also heat cells that sit on the side of the building and pre-warm the air that goes into the buildings heating systems.” In terms of products, Johnston has focused heavily on developing products that offer superior efficiency and a reduced carbon footprint. “All our sweepers can operate at a lower RPM than other machines,” explains David. “With a lower RPM comes lower noise and fuel consumption so we believe we have the most cost efficient and least polluting machines on the market.”

This R&D strategy is core to the company’s activities as it moves forward, as too is its

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Johnston Sweepers

Cheesman Products (Automotive) Ltd. Established in 1973, Cheesman has earned a reputation as a high quality manufacturer of exhaust systems and tubular components. During the last 40 years Cheesman has forged a successful relationship with Johnston Sweepers, being involved not only in the development of parts, but also in the provision of a weekly Kanban service. Alongside consistent dependability, Cheesman offers the benefit of the company’s experience and expertise, teamed with excellent customer service.

commitment to delivering an improved customer service. “It’s not solely about listening to our customers and developing solutions, but also making sure we are easy to do business with,” notes Graham. “We have become members of the Institute of Customer Service, which is there to help us support our customers and deliver a much better level of customer service.” Reflecting on the product launches and developments from over the past year, Graham is also hopeful that this will continue over the near future. “Parallel to this, from a manufacturing point of view, we will be looking at how to further the automation to ensure that we can remain competitive in a high labour cost environment with global competition,” he concludes. “To make our business more efficient and to allow us to deliver what the customer wants, when they want it.”

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Arjowiggins Creative Papers

A clean sheet Paper manufacturer Arjowiggins not only brings to market an extensive range of quality products but also a long history steeped in tradition and innovation

Arjowiggins Creative Papers Products: Specialises in the manufacture of high quality added-value papers Production sites: 7 www.arjowigginscreativepapers.com www.arjowiggins.com

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rjowiggins can trace its origins back to 1492 with the birth of Arches paper mill and after a long history of global division acquisitions and sales, the company is today a world leader in creative and technical paper. Courtesy of its 4000 employees spread across 19 production facilities, in 2014 the Arjowiggins Group turned over one billion euros in sales. Despite being heaped in history and tradition, the modern Arjowiggins is committed to continuous innovation, using cutting edge technologies to provide clients with pioneering solutions to a range of specific demands and challenges. Parallel to this the company has also been at the forefront of the move towards environmentally friendly paper.

Arjowiggins’ portfolio offering can be split into three pillars: graphic and speciality, creative, and security. The graphic and speciality division offers coated and uncoated papers, recycled papers and pulp, niche demands such as playing cards, transfer papers and tissue, and medical papers including sterilised packaging and compresses. Its creative and fine paper division specialises in corporate

communication and promotion, luxury packaging, bookbinding and official documents among other applications. Finally, its highly technical security division possesses expertise in banknote and secure papers, as well as brand and consumer protection solutions. Supporting this wide offering is a dedicated commitment to working closely with its clients to develop bespoke solutions for a range of unique demands.

At the heart of the creative paper range is the company’s Conqueror brand, which began production in 1888. The Conqueror brand is trusted worldwide for its quality and offers a complete range of corporate needs from sheets to envelopes in a variety of different textures. Next is the Curious Collection, the most innovative range of papers offered by the company, which consists of six unconventional and cutting-edge papers: Metallics, Translucents, Cosmic, SKIN, Touch and the newest addition, Curious Matter. This latter product has a touch between silk and sand and is already a success, being used by major luxury companies and innovative designers. The Collection is available from 82 to 380 gsm in 52 different colours.

The Keaykolour range introduces the company’s more rigid products with a range of high quality textured papers and boards in a range of vibrant colours. Demonstrating Arjowiggins’ environmental reputation, the Keaykolour range is available in both 30 per cent and 100 per cent recycled variations. Next up is the Rives brand, which is a fully FSC-certified and includes 100 per cent recycled options in its range of highly textured paper available in eight special textures, ten colours and from 80 to 350 gsm. The paper is perfectly suited to a range of applications including litho, screen printing, UV varnishing, blind embossing, laser cutting, film laminating, foil blocking, folding and creasing. Rives is then accompanied by Rives Sensation, which utilises a patented surface treatment to combine Rives’ delicate textures with the print performance of a coated paper.

Furthering the range with a more vibrant offering is the Pop’Set brand, which reflects the whole colour spectrum. Using 100 per cent virgin pulp and available in a choice of 31 shades, Pop’Set papers are available up to 400g and are perfect for a range of corporate communications, advertising, promotional print, direct mail and luxury packaging applications. On the opposite end

yet comprehensive range of white premium offset papers in the Inuit brand, ideally suited for corporate communications, promotional print and high-end publishing.

Completing the extensive paper offerings by Arjowiggins Creative Papers is its Creative Labels range, available in sheets and self-adhesive reels, and its digital solutions perfectly suited for both dry toner and liquid toner technologies.

In keeping with Arjowiggin’s leading commitment to environmental responsibility the entire range of its creative papers has been FSC-certified since June 2008 and many of its products are available in varying degrees of recycled materials up to

Antalis Packaging

of the scale to Pop’Set is Arjowiggins’ Opale range, which presents superior ultra wove whiteness for the perfect corporate letterhead solutions.

This is complemented by the fresh and simple

Antalis Packaging is a leading supplier of packaging throughout the UK and Europe, specialising in stock management for individual customers.

From its Livingston facility (one of 17 across UK & Ireland), Antalis Packaging manages all aspects of the bespoke packaging requirements of Arjowiggins, holding stocks and delivering on a call off basis.

Concentrating its business with a small number of strategic suppliers in each industry sector, Antalis has secured favourable trading terms. This coupled with its stockholding capability, means Antalis can purchase strategically, guaranteeing competitive and consistent pricing for Arjowiggins and the many multi-nationals it supplies.

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Arjowiggins Creative Papers

Omnia-Chem

When Omnia-Chem was formed in 1992, the key objectives were to provide innovative technical, chemical and engineering solutions to operational issues within the UK paper industry. Twenty-three years later, the company remains committed to these values and has established itself as a key partner in a wide variety of technically challenging situations.

The Omnia-Chem approach starts with a detailed technical investigation of an issue, taking input from engineers, chemists and managers closest to the ‘problem’. This input is partnered with in-depth technical and operational analysis by Omnia-Chem’s specialists, to establish root causes and develop chemical and engineering solutions.

Omnia-Chem provides programmes that produce the required results, in an efficient, dependable and cost-efficient manner, to maximise the return on investment for the customer. All chemical applications are provided with strong local support, coupled with extensive technical and engineering resources, working closely with on-site operations and technical teams.

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10 per cent. In an attempt to reduce the carbon footprint of its products in 2007 the company launched carbon-neutral versions of its Conqueror branded papers in the UK, with Germany following suit a year later. Elsewhere in the company, in February 2014 its graphic papers division successfully implemented ISO 50001 certification for energy management across all of its sites. This allowed Arjowiggins to take a more consistent and systematic approach to its already careful and responsible use of energy, which has been a central

driver in the company for much of its history.

Active throughout the globe in both a sales and production capacity, Arjowiggins is truly a world leader in its field and its approach to manufacturing a range of quality products and brands in a responsible way is central to this.

By continuing on this innovation driven journey to serve its clients with the very best paper solutions the future for the company looks positive in a challenging and highly demanding market.

Nowy Styl Group

Comfortable

success

Nowy Styl Group has grown from an office chair manufacturer to a European leader in comprehensive furniture solutions for office environments and public spaces

Nowy Styl Group Products: Office furniture manufacturer Sites: Headquarters, Krosno, Poland www.nowystylgroup.com

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roud to be a reliable business partner, Nowy Styl Group uses its accumulated 23 years of experience in the market to gain the enviable position of the third largest manufacturer of office furniture in Europe. Focused on providing a flexible approach to customer demands, the group cares for products, people and the natural environment and maintains a passion for completing tasks in a manner that guarantees success. Today the group has delivered and installed its products in more than 100 countries across the world and boasts 16 modern production plants in Poland, Germany and Switzerland, and also through joint-ventures in Turkey, Ukraine and Russia; it also has branch offices in 18 countries and an in-house project management team.

Key to the group’s leading reputation is its focus on innovation and commitment to quality,

as well as the in-depth analysis of each clients unique needs, efficiency, work organisation, ergonomics and acoustics it undertakes to deliver tailor-made solutions. This flexible approach has led to Nowy Styl Group becoming one of the most dynamic and developing furniture companies in Europe, with annual revenues reaching almost 300 million euros. “I strongly believe it is mainly our unique company culture, alongside our innovative structure and management model that has given us such a competitive edge in the market,” confirms Roman Przybylski, Chief Commercial Officer at Nowy Styl Group. “We combine the entrepreneurial spirit and elasticity with corporate efficiency to leverage support functions and manage the whole value chain.”

He continues: “Our customer base is strongly differentiated, from major multinational companies buying our own offices, to

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construction companies and smaller local organisations. To meet the varied needs of our clients, we have a portfolio of six product brands. This includes Nowy Styl, which is our historical brand that today represents a wide product range for all channels. There is also BN Office Solution, Grammer Office, Rohde&Grahl and SITAG, which represent the professional office market segment; this portfolio was increased through acquisitions. Our next product brand is Forum Seating, which includes all seating that is fixed to the ground such as stadiums, auditoriums, music and sports halls; we also have Baltic Wood, which is a three layer wooden flooring company. This is more of a financial investment that isn’t in close connection to the rest of the group, but is a great company with high-end products for the most demanding of our customers.”

The company’s latest acquisition took place in August 2015, when Nowy Styl Group signed a contract for the acquisition of SITAG AG, a manufacturer of chairs and office furniture that has its own sales structure and production plant in Switzerland. The addition of SITAG is the group’s third acquisition made within the last four years and will expand its distribution network in the developing Swiss market. This development is in line with the group’s focus on expanding its furniture portfolio and growing both organically and through acquisitions.

HOMAG Group

High-tech furniture plant in Jaslo, Poland: Nowy Styl Group produces with technology of the HOMAG Group With its decision for a new high-tech plant for the batch size one production of high-quality office furniture, innovative furniture manufacturer Nowy Styl Group has endorsed the HOMAG Group’s technological and plant competence. The latest investment by the Polish office furniture manufacturer provides seamless order-specific production – from panel infeed through to the assembly and packaging line. The impressive array of machines includes machines from HOLZMA, HOMAG, HOMAG Automation and WEEKE. Processing 4000 components per shift in two-shift operation, the plant is producing around 2,000,000 components a year - equivalent to around 500,000 items of furniture.

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Nowy Styl Group

Having accumulated a strong reputation as internationally styled designers since its inception in 1992, Nowy Styl Group has also been repeatedly recognised for its ability to deliver bespoke projects and innovative, non-standard, custom-made products. Discussing how the company takes on major projects such as the Green Point Stadium and the National Polish Radio Symphony Orchestra, Roman says: “These projects show how much capacity we have, not only in production, but in technical, R&D, logistics and project management. Projects such

Donati

Donati is a reality entrepreneur in the office chair sector at an international level.

Donati produces aluminium die-casted and injected moulded components for office chairs.

Donati provides all the creative tools and technology at high-level quality for well-designed office chairs.

Donati produces pre-tested components certified both to the highest international standards and environmental impact.

Donati is open to more varied opportunities: from customised components to shelf components to mix and match components. From a client’s idea it exclusively engineers and produces a developed project.

For continual enrichment and innovation ten per cent of the company’s turnover is invested in R&D.

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Nowy Styl Group

as these are very ambitious; custom tailored and need close co-operation with architects, acoustics experts and other suppliers. They also require huge co-ordinated assembly teams that are fuelled by perfect logistics; sometimes they require innovative structures, such as a project in South Africa where we established a dedicated

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SPV with a group of local partners.”

To further ensure high quality solutions, Nowy Styl Group invested in a new office furniture factory in 2014, complete with cutting edge technology and equipment, as Roman states: “The new office furniture factory operates a fully automatic production line, where every single detail is controlled by a CNC programme.

Moreover, we also use laser edge bending technology, which uses a laser beam to melt the surface for gluing. Our level of quality is credited to standardisation of production processes and automisation as well as robotisation. We use robots for welding, polishing, upholstering and foam parts production. We also have an automatic line for chrome plating and powder coating; for metal cutting, we use a modern combo fibre laser.”

Not only dedicated to high quality operations, Nowy Styl Group also takes its responsibility as an environmentally friendly production company seriously and strives to positively change its environment every day. To do this, it purifies 99 per cent of emitted gaseous substances through the utilisation of a system that cleans such substances by removing the chemical content and releasing the clean air outside the factory. The company also purifies 99 per cent of liquid waste it produces by filtering the waste in its own treatment plant before releasing it into the groundwater. Other examples of the company’s efforts include choosing reliable suppliers and investing in energy-saving manufacturing technologies that have cut energy consumption by up to 70 per cent. These efforts were recognised in 2015 when Nowy Styl Group won the National Champion title in the Environmental & Corporate Sustainability category at the European Business Awards 2015.

Moving forward, Nowy Styl Group will spend the next 12 months integrating its recent acquisition into the group and focus on developing a stronger presence in the Swiss market while also boosting its international network. Meanwhile, over the longer term, the group will remain focused on its mission to deliver end-to-end furniture solutions that ensure work comfort and ergonomics. It will also look to strengthen its position in the top three largest manufacturers of office furniture in Europe by caring for products, people and the natural environment. “We want to strengthen our position and become a clear leader in Europe; we also want to be the company that makes a difference in a rather conservative industry; a goal that will be achieved by concentrating on our core competences and markets and by using the learning and knowledge of a truly international company to reinforce the entrepreneurial spirit that we are so proud of,” concludes Roman.

SGB-SMIT

Power to

grow

Quality manufacturing and customer service have enabled SGB-SMIT to occupy a leading position in Europe that looks set to grow even further as the group looks towards new markets and product developments

SGB-SMIT Products: Largest pure play transformer manufacturer Sites: Six production sites www.sgb-smit.com

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long and successful history is the solid foundation for today’s SGB-SMIT Group. A relentless pursuit of market and portfolio expansion has defined the company’s progress, and a number of significant acquisitions have been instrumental to SGB-SMIT’s achievements. Today, from six production sites the company serves customers in a number of segments from power generation, public and municipal utilities and infrastructure, to industrial, railway and shipping.

A widespread portfolio presents oil-immersed type transformers up to 1200MVA and 800kv; resin-encapsulated transformers to 25MVA and 36kV; oil-immersed distribution transformers; and compact substations. However, the offering never remains stationary, as SGB-SMIT’s continuous programme of acquisition ensures the portfolio constantly expands to serve a full range of demands.

The company’s roots can be traced back as far as 1913, with the formation of the first SMIT transformer factory in Nijmegen, Holland.

“Willem Smit was one of the pioneers of energy transmission, building the first public electric lighting system in the Netherlands,” explains Jan Oelscher, CEO of SGB-SMIT.

As for SGB’s history, Starkstrom-Gerätebau GmbH was founded in 1947, with its focus on the production of oil distribution transformers. “This industry was very progressive,” notes Jan. “As experience and market demands increased so did the ratings and capacities of the transformers. By 1963, SGB delivered the first 110kV transformers.

Steady, continuously-growing experience led to further diversification and the introduction of cast resin transformers into the manufacturing range in 1979, which opened up even wider access to the industrial sector.”

In order to keep up with growing demand, in 1990 the company founded Sächsisch-Bayerische Starkstrom-Gerätebau in Saxony, Germany. “For this, a brand new factory was built to take over the complete manufacture of oil distribution transformers from the over-capacity Regensburg site,” says Jan. “The new factory soon operated under full load and has been growing constantly every year. This site can also be proud of being the only factory in Germany to still manufacture oil distribution transformers, whilst other competitors have shifted all production abroad.

“In 1995 SGB went intercontinental. AM SGB was founded to manufacture distribution transformers up to 2.5 MVA in Nilai, Malaysia,”

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SGB-SMIT

Jan continues. “Demand for quality products from Nilai was not restricted to this performance class, so AM SGB entered the medium power transformer level and now sells its largest transformer up to 35 MVA. In 2008 a new strategic step was taken in inaugurating a cast resin transformer factory, SGB Cast Resin, at the same location.”

Come 2006, SGB set its sights on completing its range of transformers and following the 100 per cent acquisition of SMIT Transformatoren B.V., SGB-SMIT Group, “Partners in Power”, came into existence. “By this point SMIT had become specialised in large power transformers with an actual range of up to 1200 MVA and 800kV, and had established a strong presence in the North American market,” notes Jan. “In the following years SMIT intensified its activities in the field of transformer services and in 2010 opened a separate location in Nijmegen to focus on maintenance, diagnosis and repair of all kinds of transformers.” In 2013, on SMIT’s 100th birthday, the company achieved the ‘Royal’ title.

With SMIT’s acquisition opening up the North American market for the entire group, SGB took the opportunity to expand its global footprint and in 2010 it opened a new assembly factory for cast resin transformers in the USA, SGB-USA. In 2012, the group welcomed OTC Service Ltd, based in Ohio, to the group. “OTC, as a well established specialist in the repair and upgrade of small and medium sized transformers represents an important partner for SGB-SMIT in North

America, which is a really interesting growth market at present,” explains Jan. “Following this, SGB-USA moved to the OTC location bringing benefits to both parties with regards to know-how and access to markets.”

Most recently, in 2014 and 2015, SGB-SMIT has continued its growth strategy with the acquisition of the majority stake of the transformer manufacturer Retrasib S.A. in Sibiu, Romania and the design company Trafo Proiect. “The main reason to acquire these two companies was to increase our competitiveness in the range of 200 MVA transformers, where in the past these units have been too large to manufacture in Regensburg and too small to make them competitively at SMIT,” expresses Jan. “In addition, Retrasib gives us better access to Eastern Europe, as well as a competitive manufacturing base. Both companies have integrated fully into our quality standards and design systems, and work hand in hand with our other European sites.”

Growth has always been a defining point to the SGB-SMIT group, and this is particularly true for the last couple of years. Jan puts this growth down to company’s core strengths: “The group combines the competitive strengths of being a high quality manufacturer with a high degree of customer orientation and flexibility.

We have a flat structure, are close to our customers, listen to their needs and work with full dedication to serve them. We also have a very

strong team to implement and deliver this.”

Product development has also been a major part of the group’s historic progression and Jan explains that this is always dictated by the changing trends in the markets. By working closely with its customers the group has also established a reputation for specialised solutions besides its conventional products, especially with the rise of the renewable energy sector. Jan points out the company’s new controllable distribution transformer, ‘RONT’ and its cast resin solutions for wind energy.

As for the future, SGB-SMIT will be committing itself to the same strategies of growth and development that have secured its present success. “We strive to continuously convince our customers with our dedication to meet their needs at highest level,” Jan concludes. “Internally, we will focus on further improvements to our processes in order to deliver consistently high quality transformers. We are rooted in Europe and we want to use this strong base to further grow here, as well as selectively strengthening our activities in Asia, North America and Africa.

Ultimately, with our state-of-the-art products and our commitment to quality we strive to exceed our customer’s expectations.”

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Apple International

A renewed

approach

Long-established Apple International bounced back from the recession with a more focused approach despite universally-felt challenges and is now starting to make an impression on the US market

Apple International Products: Manufactures food production equipment Sites: One in the UK, plus global distribution and industrial partners www.appleint.co.uk 104 www.manufacturing-today-europe.com

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ounded in 1985 by Steve Smith and Andy Fraser, Apple International celebrated a long period of growth and success supplying a range of food production equipment for the global market. At the core of the company’s product offering is its depositor machine, which incorporates a reservoir or hopper with highly accurate measuring devices and a valve for dropping ingredients onto a conveyor system. “We work right across the food industry in bakeries, confectioneries, dairies and ready meal & fast food producers,” outlines MD, Steve Smith. “From a basic machine, we gathered pace and developed other depositors into the range, which handled everything from one gram to 2000 grams. As we became more well-known in the food service industry, people wanted us to do more than just supply depositors so we then went into systems, which included conveyors, multiple

depositors, other ancillary and mechanical handling equipment.”

Building up distribution channels across the world as it grew, Apple International was represented in Australia, South East Asia, Europe, South America, Canada and the US. However, like many, the company came under pressure during the recession as overheads exceeded sales and Apple International went into administration. “The company went through a rough time but we came out the other side and have downsized the business,” explains Steve. “We now don’t have the massive overheads that we had previously; we have a quarter of the staff and are in a unit a quarter of the size as pre-recession.”

Despite this, the company has still been able to maintain its operations in selling depositor systems for food processing. “We now contract most of our work out so our components are

manufactured out-of-house before coming into us after various checks and inspections,” he continues.

“Interestingly, we still use a lot of our local suppliers from previously but they just supply us with more now! Therefore, we are still building the same type of equipment but we just do it in a different way at a reduced cost that is more manageable for us.”

With a renewed strategy behind it, recent years for Apple International have been positive.

“Before, my focus was split all over the world, but now I have been able to refocus on strong markets like the US and UK, then it’s just a case of maintaining our strong relationship with global and European distributors,” says Steve. The US has been central to this renewed focus and collaboration with a large ready meal producer in

Camozzi

Camozzi, one of the world’s leading suppliers of advanced pneumatic components and systems, has enjoyed a successful partnership with Apple International for in excess of 20 years.

Throughout this time Camozzi has supplied a complete range of components, which have then been incorporated into Apple’s food depositors. Kits of parts have typically been supplied with a single part number that helps to simplify ordering and reduce installation time. Maintenance time/costs are also reduced due to the high reliability of the components that make up each kit.

The Camozzi team looks forward to supporting Apple International for many years to come.

America is laying foundations for a successful future in the market. “We set up an industrial partnership with a company in the States called Stainless Steel Specialists Inc in Wisconsin, who operate under the name ‘Apple USA LLC’ when representing us,” notes Steve. “Through this partnership we supplied this ready meals company with some test equipment and this relationship has proved to be very beneficial for us both.”

After a period of trials and variations, the American customer awarded Apple International with a contract to replace all of its existing depositors that had been supplied by an American competitor.

“The main reason for this is that we demonstrated a much more precise and accurate depositing system than they were used to,” highlights Steve. “There are a lot of depositors

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Apple International

about but we have taken all the bad design away and used our 30-plus years’ experience to bring a lot of innovation in. This ensures that we can achieve much improved weight accuracy in our equipment than was previously available. The customer measures its efficiency in waste and the competitor’s machines were giving away up to $1500 per shift in waste material through over filling and poor depositor performance. Our

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machines have delivered an 85 per cent waste saving just by depositing the required weight, but with superior accuracy.” Overall, the contract is to replace 23 lines with seven completed so far.

Apple International recently manufactured and supplied depositing equipment onto a completely new line, which represented a total $9 million investment for the client.

“What has been special about this collaboration is the ongoing development that has been central to it from the first machine until now,” explains Steve. “All machines since the first have had various changes made to them due to the customer wanting that extra bit. Therefore, what was a fairly basic machine has developed into a very sophisticated and clever piece of equipment with diagnostics on screen, temperature readouts, etc.” With its eye on expanding into the US market, this focused, customer-orientated development has been critical to achieving its growth visions over there. He continues: “We are now in a situation where we can show the product at the Process Expo in Chicago in September 2015. Luckily, we have a machine that hasn’t been installed into a customer’s line yet and they are kindly letting us demonstrate that at the show. Effectively, this is the launch of a machine that has undergone a process of continual development over the last three years. It’s also a good demonstration of how we can work with the customer to develop bespoke solutions.”

Despite outsourcing much of its component manufacture to contracted suppliers, Apple International’s site in Hull is still set up to maintain its production levels and includes facilities for basic machining and fabrication. “Previously, we had our own CNC facilities and electrical department, for instance, but now we have almost a scaled down version of this set up.

We don’t have CNC facilities any more but we do have basic machine tools to make individual components as and when required, as well as fabrication and demonstration areas to trial machines,” says Steve. “This is supported in the States by our partner who holds spare parts in stock to supply direct to the customer quickly, as well as a support for M&E engineering.”

The economic downturn in 2008 hit the UK manufacturing industry hard and many companies were forced to re-evaluate their operations and positions in the market. Many didn’t survive, but those that did undoubtedly did so as a much stronger and robust company. Apple International demonstrates how scaling back and refocusing attention can be an alternative route to success and its long-term outlook very much reflects this. “We’re going to be looking really closely at our business in the USA alongside our partners there to increase our presence,” concludes Steve.

“At the same time we will of course continue to support our business in the UK and Europe.”

ATAG Verwarming Nederland ATAG Verwarming Nederland BV Products: Manufactures boilers Sites: One, Nederland www.atagverwarming.nl

Material

strength Innovation and unrivalled quality are the key drivers to ATAG Verwarming being able to consistently deliver awardwinning efficiency to the market

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ounded in 1948, ATAG Verwarming’s focus has always been on developing the most efficient and high quality boilers available. Through a network of over 500 ATAG Select Dealers, and construction partners, the company serves both domestic and commercial customers. “Whilst we are also looking at at renewables like solar products, our major focus always has been and will continue to be on high quality, gas condensing boilers,” explains Jan Henk van der Wijk, Marketing Manager for ATAG. “Our strengths lay firmly in the use of materials in our boilers. By this, I refer to the highest quality of stainless steel used in our components and this is why we have unrivalled quality compared to our competitors. Whilst this may be more expensive in the short term, the lifetime longevity afforded by these materials

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makes the boilers a far more cost efficient product in the long-term.”

Efficiency is the most important driver at ATAG and the company’s R&D operations are targeted to deliver this on a continual basis. “Our R&D department is made up of 10 people in our office whose job is to solely focus on innovation,” continues Jan Henk. “Their most important aim every day is to increase the efficiency of our boilers without sacrificing comfort.

This is the pillar of our company.” The boiler industry is competitive with high quality and safety standards ensuring that there are no bad boilers available in the market. However, through its consistent and relentless approach to innovation and efficiency ATAG has established itself as a consistent leader in becoming the recipient of Holland’s best boiler manufacturer award for six years running. This is reinforced by a number of corporate awards,

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based on the company’s financial performance, such as Best Managed Company.

“The Consumentenbond is a leading independent organisation that tests products and is driven by efficiency when assessing boilers,” highlights Jan Henk. “This achievement is realised by our patented heat exchanger – the heart of the boiler – which is made from the highest quality stainless steel. The heat exchanger is based on a proprietary single platform technology and again efficiency is the key word for its development.”

With superior efficiency offered by its products, the company currently has three ranges available on the market: the A-, E- and Q-Series. The A-series sits as a basic, starter boiler and offers unrivalled efficiency without some of the more advanced features in the range, and the Q-Series is skewed more towards comfort by ensuring that there is extra heated water available on demand.

However, the most important boiler in the range is the award winning E-Series. “The E-Series’ major USP is its focus on increasing efficiency without the sacrifice of comfort. Comfort, as in warmth, is vital for our customers so maintaining this is absolutely key to us,” outlines Jan Henk. “A

ATAG Verwarming Nederland

major innovation within the E-Series is the use of an Economiser, which is exclusive only to ATAG boilers. This is a second heat exchanger that sits within the boiler and profits from the warmth of flue gases. Instead of being released through a chimney, as would normally happen, the heat from these gases is captured by the second heat exchanger to help warm up water and allows the boiler to achieve even higher efficiency.”

With innovation being driven throughout the company’s boiler products at an unrivalled pace, it is no surprise that this development extends out into associated products and this is evident

in the company’s ATAG One product. “The ATAG One is a Wi-Fi thermostat so that the consumer can adjust the temperature remotely. This is developed from the basis of making life easier for the customer,” says Jan Henk. “However, an added benefit for both the end user and installer is that the installer can remotely monitor the boiler through the connection of the ATAG One panel and an online database. This enables them to see any potential faults in real-time and recommend maintenance accordingly. Again, this is exclusive to ATAG products and gives the consumer the added peace of mind as to their boiler’s performance.”

The future for ATAG looks set to be positive, but Jan Henk notes that a changing energy landscape will lead to interesting developments within the industry over the next few years.

“The main challenge for us is the change in thinking about

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ATAG Verwarming Nederland

ARGOMM SPA

AR Group - headed by Italian based ARGOMM SPA - stands for custom products for high-demanding industries with a strong focus on sealing solutions.

In-depth knowledge in polymer based material behavior and transformation, managing state-of-the-art molding technologies for elastomers, technopolymers, thermoplastic elastomers, LSR, plastic magnets and 2K-3K components, delivering co-design and raw material development expertise, leveraging on lean production and quality management principles as well as adapting the supply chain to a global scenario, makes AR Group’s value proposition highly reliable and its delivery streaming through – but not limited to - automotive, electro, gas & water management, white and general industry.

The Group employs 750 people and will turn over 75 million euros in 2015.

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energy and how it is used,” he says. “The focus is shifting more into the reuse of energy, durable solutions and thinking about gas-to-power solutions.” Despite this he remains confident and committed to the security of the company’s strategy in a country that has such a strong and robust gas infrastructure presently defined by longevity. “We are first and foremost a boiler manufacturer,” Jan Henk adds, “and whilst solar products are becoming more important to us, our key role will remain for the next 20 years at

least with providing gas solutions.”

With this in mind the next year for ATAG will see the launch of a new more compact and more sophisticated range of boilers aimed at becoming the next generation in boiler efficiency.

“Again the focus for this will be efficiency through material use,” Jan Henk concludes. “In the longer term we want to continue setting an example with sustainable development. This has been very important to us for the last 30 years in offering both green products and long-lasting ones.”

Tomburn

Coatings of many

colours T Tomburn is the largest independent applicator of architectural powder coatings in the UK and has worked on many significant projects both at home and further afield

Tomburn Ltd Products: Architectural powder coatings Sites: Two in UK, one in Czech Republic www.tomburn.com

he organisation offers clients access to its knowledge of a wide spectrum of finishing and accompanying services, accrued from over four decades of industry experience. These customers are market leaders in their own right, coming from industries such as mobility, rail, ventilation, solar shading, street furniture, glazing, fencing and electronics.

Carl Tomlinson, Operations Director explained how the business is organised into three divisions and gave further details of their services: “Tomburn Limited was formed in 1998 by John Tomlinson and David Hepburn when they acquired the UK business from Heywood Williams plc in a management buyout,” he began. “The business now operates from two UK divisions – Birmingham Powder Coatings (BPC) and LBL Finishers (LBL) - and it has a Czech subsidiary called Tomburn CZ s.r.o.”

Now operating from a 45,000 square foot factory, situated in the south of Birmingham at the centre of the country’s motorway network, BPC originally started as a powder coating company

National Assembly of Wales

working on British Army barrack bed frames.

“These were needed in black as standard issue, and beige, which is a sand colour for use in desert environments,” said Carl. “Following experience gained in this area, the business progressed to painting hospital beds before then moving into the automotive industry. This was quickly followed by a move into the architectural field.

Today BPC is widely acknowledged as one of the leading applicators of quality architectural powder coatings, with a growing reputation for added value activities such as the assembly of solar shading modules, taping of coated profiles and logistics. It is also the longest continuous holder of a Syntha Pulvin applicator’s licence, which enables it to offer warranties of up to 40 years.”

The second division, LBL Finishers, was created from the merger of three other companies: Lofting Stoving and Engraving Ltd, Banstead Finishers Ltd and Lustre Stoving Enamels Ltd. and has built on the traditional industrial, rail and architectural

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The Wall, Ultrecht, Holland

Costa Coffee, Liverpool

Syntha Pulvin

Syntha Pulvin has been trusted by specifiers across Europe for over 40 years. Syntha Pulvin offers the highest quality of powder coatings available to architects and building construction professionals and no matter what building component you need to protect, Syntha Pulvin has an architectural powder coating to meet your unique needs.

Following on from the success of the Collection 10 and 12 range of exclusive metallic colours, Syntha Pulvin is now launching Collection 15, which puts its knowledge of architectural colour trends at your fingertips.

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markets of these businesses. The factory in Portsmouth now also serves the mobility, fencing and filtration markets.

Finally comes the newest addition, which was opened in August 2008. Said Carl: “Tomburn CZ, located just north of Brno in the manufacturing

heartland of the Czech Republic, coats and shotblasts both aluminium and steel. As well as serving the mobility market the business is growing its reputation for coating large, complex fabrications for the agricultural, heating and industrial equipment markets. Tomburn CZ plans to expand into the European architectural market and install manufacturing and assembly operations.”

United by a dedication to quality and service, the three divisions of Tomburn are also able to offer insights to clients about current market conditions, trends and advice on the best options for their particular requirements. “As active members of ALFED and CAB, we benefit from up-to-date insights into our markets and from contact with key players in the aluminium value chain,” Carl confirmed. “So for example the construction market has been very busy over the summer period, but we are expecting to see that slow down as we enter autumn/winter. Our other markets are showing a strong trading level.”

To give further details of what Tomburn can offer, Chris Mansfield, Commercial Director gave some specific examples of recent contracts: “We are currently supporting an aluminium systems

Tomburn Ramada Encore Hotel, London

business by coating approximately 30 tonnes of extrusions a week,” he began.

“We are also involved in a project where we are cutting and preparing aluminium extruded solar shading items before painting them in a specially formulated, high durability powder coating and packing for transit to the Middle East.

“Furthermore, we have developed - in conjunction with our customer and powder supplier - a bespoke shot blasting and coating solution for mild steel that provides an

Zlote Tarasy, Warsaw

aesthetically pleasing product with excellent abrasion resistance for the mobility market.”

It is clear from Chris’ comments that Tomburn values close working relationships with both clients and suppliers, and as he explained, the company’s offering is more than a simple service: “We are offering a coating system,” he emphasised.

“We take our customers’ free issue materials, pre-treat these using speciality chemicals and apply the powder over the treated aluminium. All stages of the process have to be in control for the

system to work and our suppliers regularly test our process, and the work we produce to ensure we can all be confident of the market leading warranties we offer. We also work alongside paint suppliers to develop new finishes to keep our customers ahead of their markets.

“Our ability to service and exceed our clients’ expectations has accounted for solid partnerships lasting in excess of 30 years.”

This dedicated process is supported by a range of state-of-the-art facilities that have been the recipient of investments and improvements in recent times. “Over the last five years Tomburn has been overhauling all its plant to enable us to reduce energy consumption, improve quality and productivity and maintain service levels,” said Chris. “We are currently completing this process at BPC, and completing this investment in order to maximise our quality, and capitalising on the market opportunities this offers, are high priorities for the business going forward.”

In order to ensure that the best value is extracted from these investments, Tomburn trains its staff in all procedures and monitors compliance through a stringent programme of internal audits, which are reviewed at board level monthly. “We are also approved by all major powder suppliers, who audit us regularly,” added Chris. “We are also audited by suppliers and work closely with them to build their requirements into our systems.”

With the ongoing investments and some highly impressive contracts under its belt including the National Assembly of Wales, Costa Coffee in Liverpool, The London Underground, The Pestana Hotel in London and The Wall in Utrecht in Holland, Tomburn’s next few years look set to be exciting. Chris concluded with some further plans for the future: “As the founders of Tomburn start to plan their retirement we are building a new management team to grow the UK and CZ businesses. We have identified target markets, which will enable us to broaden our sales base, and we will be looking at new technologies to enable us to offer a broader suite of services.”

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TOMRA Sorting Solutions

Innovation for the

world

Norwegian sorting equipment manufacturer TOMRA demonstrates the importance of innovation as it sits at the top of its field in a number of industries around the world

TOMRA Sorting Solutions Products: Designs and manufactures sensorbased sorting technologies for the food, recycling, mining and other industries. www.tomra.com

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oday’s TOMRA Sorting exists as a global leader of sensor based solutions with the highest market share across its sectors, supplying customers around the world with sorting and processing solutions to optimise resource productivity and deliver a more sustainable process.

The TOMRA group, with 2400 employees, turned over 550 million euro in 2014.The Norwegian company has cemented its position in the market through a programme of cutting edge innovation and rapid growth.The company began its life of success in 1972 when brothers Petter and Tore Planke set out to solve a problem encountered by businesses across the country that wanted a system to return empty bottles.The brothers set about producing their first innovation and by the end of the year they had 29 machines installed across Norway, and a year later they had distribution agreements throughout the rest

of Europe and the USA. From that point on TOMRA has grown from strength to strength, remaining ever committed to its ability to innovate with new solutions that put it ahead of its competitors. At present approximately 11,500 TOMRA Sorting units are installed in over 80 countries around the world.

Throughout the start of the twenty-first century, TOMRA embarked on a strategy of acquisitional growth to diversify into the sorting industry to grow the business and increase revenue. During this period the company added companies such as TiTech, Orwak, Commodas, Ultrasort, Odenberg and BEST Sorting into its portfolio, and the company entered the food, mining, and speciality products sectors and complemented its already strong recycling offering.

One thing that has remained a constant in TOMRA’s life is innovation. “Technology is the cornerstone of everything we do,” says Executive Vice President and CTO, Head of TOMRA Sorting

Mining equipment Com Series

Comas Solutions,Volker Rehrmann. Illustrating this and indicating the success of the company’s move into the food industry; in 2015 TOMRA became the recipient of the Innovation Award at the World Nut and Dried Fruit Congress in Turkey.The award was for the company’s new Nimbus BSI technology, a free fall sorting machine with Biometric Signature Identification (BSI), which meets the high

expectations and requirements within the food industry by removing unwanted material.

TOMRA also won an international design award for its common user interface.The TOMRA CUI is a new and innovative user interface design that makes TOMRA sorters more accessible, and easier to use and operate.

However, innovation at TOMRA does not stop

Comas, being the world’s leading company in tobacco machinery, understands the importance of delivering tobacco free from foreign matters.

As TOMRA is the most outstanding company in offering sorting solutions, it came quite naturally for the two companies to join forces.

Thanks to this co-operation, now a primary line can be provided with an integrated classification system that combines heavies separation, string removal, a mono-layer flow with a sophisticated optical sorting system.

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TOMRA Sorting Solutions TOMRA Care

with the machines.TOMRA Sorting Recycling has launched a new integrated range of support services to deliver enhanced commercial benefits to its customers.

Called TOMRA Care, the company now provides a comprehensive package of services, and has 28 component elements covering the areas: process consulting, system testing, financing, insurance, staff training and upgrades.The new offer has been specifically designed to ensure customers experience a tailored service that enables them to achieve maximum return on investment.

Peter Geisler,TOMRA’s Service Director Recycling, said: “We understand that the needs of our customers are driven by the requirements of the markets in which they operate.This has allowed us to further enhance our existing strong customer service offer to reflect those needs. Our objective with TOMRA Care is to enable our customers to consistently achieve the highest levels of productivity with the lowest downtime, whilst simultaneously managing costs.”

In addition,TOMRA was recently recognised as ‘the European Business of the Year’ in the category of

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Manufacturing facility, Slovakia

companies with a turnover of 150 million or higher.

“Innovation, ethics and financial success were all part of the judging criteria and are very important to TOMRA, therefore we were extremely happy to receive this award,” highlights Volker.

TOMRA Sorting has 16 test centres worldwide, a large research and development department and a shared service network to ensure its customers benefit from ongoing innovation and constant care.

Following a successful period of acquisitional growth, in 2012 TOMRA initiated a strategic programme of rebranding to bring the company’s new divisions under the TOMRA brand umbrella.

The new vision was set in place in order to galvanise the combined strength of the various subsidiaries.

Commenting on the rebrand VP Head of Brand Lorraine Dundon said: “By completing the rebranding process, we are significantly increasing the visibility of TOMRA worldwide.”

Present market conditions are positive for TOMRA across its business streams with strong sales noted in the food, recycling and mining divisions.

To support this continued growth, the company has recently opened up a new subsidiary in the

Nimbus BSI

Müller Maschinentechnik GmbH, based in Dueren/ Rheinland has successfully established itself since its founding in 2001 as a systems and components supplier.

Our core business is the pneumatic and valves technology.

Combined with our capabilities in mechanical engineering and the experience in recycling technology, we provide complete customer specific solutions.

With our specially trained staff and a network of selected international quality manufacturers and in constant dialogue with our suppliers and users, we ensure a continuous improvement of the products and the service offering.

Since 2003 we are a strong supplier for Tomra Sorting.

Customized Manifold with MAC High Speed Bullet Valves ®

Müller Maschinentechnik GmbH - Dueren - Germany www.mueller-maschinentechnik.de

Commonwealth of Independent States (CIS) with a new office in Moscow.The new expansion begins with a focus on the company’s recycling division providing the latest waste sorting technologies to a market that contains over 250 million people.

However, as Volker highlights: “Our Moscow office will also support the continued growth of our mining and food sorting businesses in the market.”

The current atmosphere at TOMRA is marked by excitement and positivity as it heads toward what is likely to be another year of record sales. Innovation and quality of product and service has defined the company’s historic success and over recent years considered acquisition has complemented this as the company takes a journey to become a market leader in a variety of sectors around the world. Crucial to TOMRA’s future success however, is this ability to continue to innovate and provide a high quality product and service program. With this in mind, TOMRA Sorting looks set to maintain its position as a global leader for a time to come.

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Our objective with TOMRA Care is to enable our customers to consistently achieve the highest levels of productivity with the lowest downtime, whilst simultaneously managing costs www.manufacturing-today-europe.com 117

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DesleeClama

Living the dream Sleep solutions provider DesleeClama’s commitment to customer satisfaction through research and development has resulted in strong industry recognition, with three innovation award wins and a commendation in 2015 alone

DesleeClama Products: Knitted and woven mattress fabrics Sites: Belgium, Romania, Estonia, the US, China, Indonesia, Brazil, South Africa and Poland www.desleeclama.com

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ounded by Maurice Deslee in 1928, the inception of Deslee enabled Maurice to merge his love for beautiful fabrics and design with his passion for craftsmanship and innovation.

Maintaining his legacy to this day, the Belgium headquartered DesleeClama continues to focus on delivering high quality mattress fabrics with exquisite designs to the market; in addition, it also searches for new technological opportunities that will ensure ongoing innovations in a competitive and demanding industry.

Aware that the bedding industry undergoes constant changes, DesleeClama set up a state-of-the-art dedicated Innovation & Design Centre (iDC) in 2012 to enable swift responses to new trends and technologies. This strategic development has proven fruitful for the firm, as it has proven its ability to produce the mattress fabrics that its clients are looking to provide to end users. To make these innovations a reality, the company’s engineers develop innovative mattress fabric and cover concepts that take advantage

of researched opportunities that are arising in different markets.

Since Autumn 2012 the company has launched a new collection, twice yearly, with a new look and feel for mattress manufacturers across the globe. Each collection is divided into five styles, with each style representing a particular design and colour range to inspire sleeping solutions; this diversity enables DesleeClama to target the demands of a specific region, while also focusing on various other market segments.

This ever increasing range of sleeping solutions resulted in three award wins at the prestigious Interzum 2015 exhibition in May, in which a total of 269 design entries from 21 different countries presented their trendsetting innovations. The first award, the Best of the Best, was given to DesleeClama for its new generation of knitted mattress fabrics that yield and support in every perspective and position. The product, named Biaxial, can stretch up to 50 per cent in every direction and recovers from any kind of pressure to revert to its original shape, even after several

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DesleeClama

years of use. The Best of the Best award is particularly impressive as only nine products have received the accolade so far, and Biaxial is the only innovation within the bedding industry to win.

On top of this, DesleeClama won two high product quality awards for its DC Metamorphosis product. The fabric is sound absorbing and can be attached to the frame of a stand or to hoist points mounted on a ceiling. With its stretched surface, DC Metamorphosis can also be used for projections as it fits around any curve or shape without so much as a seam, stitch or fold.

“Metamorphosis is a new business idea that is a small step away from our core business offering.

It is a sound absorbing, fire retardant fabric that repels dust and has self cleaning properties.

We were the only booth at the exhibition with a sound proof fabric as a surrounding and we designed it all ourself to make a statement that it can be used in real interiors. Since the exhibition we have been in discussions with architects who are interested in making Metamorphosis a soundproof decoration behind a bed, for example,” says Ben Ducatteeuw, Director at DesleeClama’s dedicated Innovation and Design Centre.

The second high quality product award winner was DoubleSided, an innovative range of knitted fabrics that can be used on both sides to create two different mattress concepts with one and

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the same fabric. The innovative product allows consumers to change their sleeping environment by simply turning their DoubleSided mattress inside out and have, for example, refreshing moisture management functionality on one side of a cover and warm Merino wool to the other.

In addition, the company has taken a global yet local approach to operations and today ensures close customer relationships thanks to its wide reaching production plants in areas such as Belgium, Poland, Romania, Estonia, the US, Brazil, South Africa, China and Indonesia.

This local presence has given the company a competitive edge in the market as everything that is developed and validated at the iDC centre can then be spread out across the world through production at any one of its factories. “This means that if a customer sees a product they like at an exhibition anywhere in the world, they can then get this product manufactured at the plant most suitable for them,” explains Ben. This global presence also means that the company can gain enviable knowledge of the local sleeping needs of people in all areas of the world.

More recently, the company took the strategic decision to open a new production plant in Poland, says Geert Flament, commercial director of DesleeClama Europe.“It really is a continuation of our strategy to be a local yet connected global company with the same global quality procedures in all production plants. Poland is a very important

area for us, as is Germany, which is nearby.

“With the new plant opening, DesleeClama has been growing at a significant speed this year with an increase in employee numbers and new machines in place. We have never invested so hugely and so quickly in new machinery.”

Moving forward DesleeClama will continue to support the establishment of its plant in Poland while also seeking further opportunities to expand into new strategic areas. “Furthermore, the company will focus on investing in new technology to ensure further innovations can be produced in the production sites while new innovations are created in the iDC,” concludes Ben.

TS Tech UK

Engineering

comfort

With extensive and growing operations across the globe, TS Tech’s commitment to quality and close customer relationships positions it nicely to bring on board new OEM customers

TS Tech UK Products: Global manufacturer of automobile interiors Sites: 70 facilities in 13 countries www.tstech.co.jp

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ounded in Japan back in 1960 and establishing its first overseas operations in the US in 1977, TS Tech has grown to become a global manufacturer of automotive interiors, predominantly seats, with a number of high profile names present on its client list. Spread across 13 countries, 70 facilities and through 44 subsidiaries, over 15,000 employees generated revenues in excess of 4.5 billion Japanese Yen in 2014. Seat production, for both automotive, motorcycle and other applications like jet skis and medical, accounts for 89 per cent of the company’s overall sales with the rest coming from other interior products like door trims.

The automotive industry is by far the largest market for TS Tech, however, with 97.5 per cent of sales in 2014 accumulated from it. “Our main customer is Honda, to whom we supply interior seat systems for around 76 per cent of their global automotive production,” highlights TS Tech UK Director, David Stone. “We have also recently commenced production in Europe and South America to supply VW, as well as motorcycle seats to Harley Davison in North America.”

Its relationship with Honda is highly significant for TS Tech and is

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‘‘

The combination of styling challenges and use of ‘natural’ materials do not always lend themselves to that of mass manufacturing techniques therefore a high level of detail, skill and control is required to ensure a quality product

a really strong foundation for its aspirations to expand its business to other automotive OEMs. “We are involved in the design and development of the complete seat assembly from concept to mass production,” says David, explaining the depth of work the company provides for Honda.

“Having developed this relationship with them over many years, we understand the technical requirements and quality standards expected.

Through our expertise in product development and process design, we are able to deliver a quality product that satisfies the customers’ requirements, at a competitive price.”

This expertise and ability to work close alongside its customers’ needs is TS Tech’s core strength, particularly when it comes to the many challenges posed by the design and manufacture of automotive seats. David outlines: “Automotive seating systems consist of complex safety critical features that require careful handling, preparation, installation and testing whilst maintaining 100 per cent traceability. The combination of styling challenges and use of ‘natural’ materials do not always lend themselves to that of mass manufacturing techniques therefore a high level of detail, skill and control is required to ensure a quality product.”

Demonstrating this attention to high quality products, in 2012 TS Tech was named as number the number one supplier in a US survey, carried out by J. D. Power, for seat quality and satisfaction.

With worldwide R&D, service and production sites accounting for an extensive range of expertise and competencies, the company is able to uphold its commitment to quality through cutting edge manufacturing facilities and continuous investment. “All of our production facilities are equipped with state-of-the-art

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TS Tech UK

automated welding systems and assembly lines, along with automated inventory control systems for the storage and sequencing of products prior to delivery,� comments David. “The company has also invested in advanced technologies, such as laser welding and automated weld bead

detection, demonstrating its desire to maintain a market leading competitiveness.� To facilitate this approach to continuous improvement, over the coming months TS Tech UK will be moving towards achieving and implementing TS16949 automotive quality management accreditation.

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TS Tech UK

“This is to expand our non-Honda sales to 20 per cent of our total business turnover by 2020, so to this end we are actively seeking out opportunities with OEMs in all regions.” As for the more immediate future, the company will be gearing up in preparation for the launch of Honda’s new Civic model in 2016. “In the UK we are currently in the preparation phase for the model, which will be introduced for export to both Europe and North America,” he continues.” This will have class leading safety features along with new styling and weight saving technologies, and thus will be another good opportunity for us to demonstrate out leading abilities to design and manufacture, on-mass, bespoke solutions.”

However, it is not just down to the company’s own operations that it is able to achieve this high level of quality and David is keen to point out the strength in its complete supply chain. “Whilst we have a number of core competencies within the group, such as cut and sew for trim cover and frame welding, our supply chain is quite diverse, supplying injection moulded and pressed parts, as well as electronic and foam products,” he notes. “Suppliers are both local and global, depending on a number of factors, ensuring that quality, cost and delivery targets are consistently met.”

Gaining recognition and building on its reputation for high quality and bespoke manufacturing capabilities is crucial to TS Tech carrying out and achieving its 2020 vision. As David explains:

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Gooch & Housego

On the right

wavelength

A world leader in its field,

Gooch & Housego researches, designs, engineers and manufactures advanced photonic systems, components and instrumentation for applications in the Aerospace & Defence, Industrial, Life Sciences and Scientific Research sectors

Gooch & Housego Products: Photonics systems Sites: Eight sites across US and UK www.goochandhousego.com

I

ts expertise extends from research through the development of prototypes to volume manufacturing and enables innovation and effective manufacturing in the aerospace & defence, industrial, life sciences and scientific research (Big Science) sectors.

Researching and manufacturing in eight sites across the US and UK, G&H is an expert across a uniquely broad range of photonic technologies – crystal growth, optical materials processing, acousto-optics and electro-optics, fibre optics, DFB laser modules, precision optics (thin-film coating, birefringent optics, non-linear, planar and aspheric), RF driver electronics in addition to light measurement and calibration solutions.

When combined with the company’s optical, mechanical, electronic and software design capabilities, G&H is able to provide complete optical system design, engineering and manufacturing services, if applicable on an ITAR / non-ITAR basis, with COTS or bespoke products.

To give more of a specific example, in the Industrial area, Gooch & Housego serves a number of markets, including: • Industrial Lasers for materials processing applications • LED and Display testing for commercial and industrial applications in the lighting,

automotive and consumer electronics sectors as well as for aerospace & defence • Metrology for laser-based, high-precision, non-contact measurement systems • Semiconductor for lithography and test and measurement applications • Sensing for applications including strain, temperature and pressure sensing • Telecommunications specifically for high reliability and high performance applications The broad range of expertise found at the organisation has been accrued over almost seven decades in business. When it was founded in 1948 its core skills were centred on manufacturing

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scientific optical components and crystalline materials, and these skills are still very much at the cornerstone of the current operations at Ilminster with global sales of acousto-optics, crystal optics and precision optics.

From these origins as a craft-based optical engineering company rich in practical optical manufacturing skills, G&H has undergone a transformation over the last 20 years into a high-technology photonics business through an acquisition policy of the best-in-breed companies in individual technology areas. The company now has manufacturing sites in the US in California, Florida, Massachusetts and Ohio in addition to its three UK facilities located in Ilminster, Glenrothes and Torquay.

In 1997 Gooch & Housego was admitted to the alternative investment market (AIM) on the London Stock Exchange. Today the company also includes sales offices in France, Germany, Hong Kong, Japan and Singapore with additional representation by a global network of distributors.

The transformation mentioned above involved a series of strategic acquisitions, beginning in 1995 with Optronic Laboratories. The two latest were added in 2013, with the purchase of both

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Gooch & Housego

a Scottish and a Greek company. Spanoptic Ltd’s manufacturing capabilities in the area of aspheres and infrared optics enabled G&H to offer a more complete range of precision optical products. The company was founded in 1976, employed 60 people in a 1000 ft² / 90m² facility in Glenrothes, Scotland – just north of the Firth of Forth and 50 miles from Edinburgh.

Meanwhile Constelex Technology Enablers Ltd, an Athens, Greece, based designer and manufacturer of advanced photonic systems was purchased to boost G&H’s Systems Technology Group (STG) and its remit of developing a higheradded-value capability at the sub-systems and systems level. The Constelex acquisition brought added expertise in the area of satellite and space photonics.

The Systems Technology Group The Systems Technology Group (STG) was established in 2013 to function as a separate business unit to design, develop, and prototype systems-level products. Its multi-disciplinary team, with expertise in mechanical, electronic, and software design and modelling, is integrating these technologies with G&H’s expertise in photonics.

The STG accelerates G&H’s move up the value chain by providing a strong pipeline of component and sub-systems.

The STG relies on government funding for some of its work, although not all the grants it receives are from the Government. These funded programmes are strategically selected and managed to create lasting value, and they need to lead to application targeted technology development and viable products. The STG is currently focused on OCT, fibre optics in the general sense, which includes lasers, sensing and also satellite communications.

The defence and avionics markets are two of G&H’s largest business sectors and have been important drivers for its investment in operational quality and programme management.

As the defence sector focuses on value and sustaining its wide array of platforms, G&H sees strong opportunities for photonics as a superior replacement for many existing technologies.

In addition, the STG is actively developing erbium-doped fibre amplifier (EDFA) systems for next generation satellite deployment to enable broadband satellite connectivity. Building on its successful use in science missions, photonics is in the process of being qualified for widespread applications for both satellite-to-satellite communication and on-board satellite data processing and routing.

G&H’s strategy is to position itself as a lead supplier of space photonics solutions by continuing to work with major government agencies

and contractors on groundbreaking scientific demonstrations.

Ultimately, the organisation believes that the high-reliability design and production of components and systems for satellites under the stringent requirements of space flight environment has general applicability to a wide range of other defence and commercial avionic markets.

It also believes that life sciences applications, with their worldwide markets and strong benefits

to society, offer the largest potential for G&H’s expansion. G&H is the established leader in fibre optical subsystems for optical coherence tomography (OCT). OCT has now become a standard ophthalmic diagnostic tool and is being deployed into multiple other applications such as cardio and cancer imaging. In order to pursue its ambitious plans for the future, G&H is investing in targeted bio-medical applications, developing new products and capabilities.

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Airius Europe

Causing a stir and reducing heating and cooling costs Having proven itself with major clients around the world, Airius’ innovative energy saving products are just beginning to become accepted by the market and the future looks set to take off

Airius Europe Ltd Products: Manufactures specialist thermal destratification fans Sites: one (UK), one (US) www.airius.co.uk 128 www.manufacturing-today-europe.com

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irius was established in 2004 and set out to develop a destratification product that would complement and enhance conventional HVAC systems. Unlike its competitors Airius’ unique nozzle design and patented stator vein technology creates a tight column of air from floor to ceiling in order to equalise the temperature.

Stephen Bridges, Managing Director of Airius Europe explains: “The unique way in which air is moved using the patented stator vein technology, encourages up to 15 times more air to be circulated through entrainment. This huge volume of slow air circulation achieves the most efficient and effective method of destratification available.”

A combination of innovative and continual R&D along with the use of the highest quality materials and motors enables Airius fans to achieve great results whilst requiring very minimal power usage making them very energy efficient.

Despite massive cost savings on energy claimed and an average return on investment for six to 24 months, Stephen admits it has been a challenge to get the message across and convince people of the technology’s effectiveness. “It took us five years to overcome the British conservatism and it is only when major companies like Marks & Spencer, Morrison’s and Boots conduct long-term trials and then buy, that anybody pays attention,” he says.

Today, however, Airius’ client list includes British

Airways, Mercedes Benz, Siemens and Jaguar Land Rover amongst a huge array of other high profile, international companies. Combine this with the fact that globally, the company has sold over 100,000 units, which have saved over a billion tonnes of carbon so far, and it is no surprise that the market is beginning to catch on and sales for Airius are increasing at a rate of 50 to 60 per cent every year.

“We supply the only destratification fan available that is suitable for ‘noise sensitive’ environments,” explains Stephen. “By that I mean they could be used in an office, a church, a retail outlet and so on, because they are quiet enough to avoid being disruptive. We have a standard range, which accounts for about 95 per cent of our sales, but also a designer range for architecturally sensitive applications and we have various bespoke items, which are specially designed to fit a particular purpose.”

One application where the company’s destratification fan solves a major problem is in the supermarket segment. “One of the age old problems has been the temperature variations in supermarkets caused by the ‘spillage’ of cold air from freezer and chiller cabinets which can result in extreme variations in temperature,” notes Stephen. “Conventionally this would be addressed by ducting to recirculate the air, but this isn’t hugely effective. We approached Morrison’s and suggested that we could solve this issue and they agreed to run a two-year trial, the results of which they didn’t

believe until they commissioned independent experts to evaluate the trial.

They even invited their freezer/chiller cabinet manufacturers to come in and evaluate their chiller units due to fears that the technology would adversely affect the equipment. However, they now claim that it actually increases their efficiency by 15 per cent, as well as significantly reducing heating/cooling costs.

As a result we have supplied well over a million pounds worth of equipment to over 400 stores in the last three years.”

Airius is also in a trial phase with Marks & Spencer to supply the new bespoke Narrow Aisle Series, which has been specifically designed to suit the narrow aisle configurations found in retail outlets. “This series has taken over two and half years to develop and we have invested about a quarter of a million into it so far,” outlines Stephen. “There are not many companies of our sort that can and will react like that to demand. On average, we launch two to three new products every year to address specific problems. I really want to get the message out there that if you have an air circulation problem, we will solve it for you, even if we have to develop a new product to do the job.”

To date, the company has spent $11 million on product development.

Trailblazing projects are rife in Airius’ ever-increasing project portfolio. By working with Boots it has demonstrated the products’ effectiveness at cooling solutions - it has reduced cooling costs by 40 per cent and overall running costs by 35 per cent. Internationally, Airius has recently moved onto the second stage of trials at the Petronas Towers in Malaysia, which Stephen is confident will lead to significant sales.

“We sell more destratification fans than other company in the world primarily due to our focus on what our customers want but we are still a very tiny player in the HVAC market,” concludes Stephen. “Our ambition is to become recognised by this industry as the first-stop solution to resolving a client’s building comfort issues and reducing HVAC costs and carbon emissions. We have begun to win people around and hope that over the coming years the reputation we have gained with our customers spreads out into being completely accepted by the HVAC industry.”

Our pallet and bulk storage warehouses have 12,000sqft of space.

Situated in the centre of the south coast just eight miles from Bournemouth with easy access to the ports of Southampton and Poole, and excellent road links to London, the Midlands, North and the West Country.

Our dedicated storage and distribution facility is equipped with STORE PRO which controls both inbound and outbound pallets and our Pick and Pack operation.

East Dorset Storage & Warehousing Ltd with it’s small dedicated management team and work force is committed to supplying a first class service to all our customers at all times.

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Services we provide: l Pallett Storage Pick and Pack l

Storage Warehouse

Tel: 01202 891091 info@eastdorsetstorage.co.uk www.eastdorsetstorage.co.uk East Dorset Storage & Warehousing Ltd Unit 79, Condor Close, Woolsbridge Ind Est Wimborne, BH21 6SU.

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Valtra

Solid

success

With a global reputation for reliability and efficiency behind it, Valtra continues as a pioneer in the agricultural industry with award winning and innovative machines

Valtra Products: Tractor manufacturer Sites: Two – Finland and Brazil www.valtra.com www.agcocorp.com

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ow part of globally leading agricultural equipment and off-road engine manufacturer, AGCO Corp, Finland-based Valtra is the leading supplier of tractors to the Nordic region and enjoys a robust reputation in over 75 countries around the world. Able to trace its roots back to 1832, the company began manufacturing tractors as Valtra in 1951. Today, it employs 2100 employees around the world, and manufactures 24,000 individually tailored tractors a year from its two facilities in Finland and Brazil.

With a focus on continuous improvement and innovation, Valtra currently produces a wide range of tractors for a variety of needs and applications within the agricultural market. From the light and nimble all-purpose A- and N-Series machines

through the hugely successful T-Series workhorse to the large, heavy duty S-Series, Valtra is able to tailor each product with a range of AGCO engines and options to suit every demand.

The company currently operates out of two manufacturing sites, one in Suolahti, Finland and the other in Mogi das Cruzes, Brazil to serve the South American market where Valtra’s reputation is growing. Operating, testing and building lasting relationships with customers in both regions, which together represent opposite extremes in operating conditions, the company is able to develop the most reliable and efficient machines in the agricultural industry.

The strengths of Valtra dig their roots into its Nordic tradition. Developing agricultural equipment in harsh and variable conditions has resulted in a portfolio of products that benefit from innovative expertise in quality and reliability.

This is enhanced by the company’s commitment to forging strong relationships with its customers to help overcome any challenge. Innovation sits at the heart of AGCO and Valtra alike, and this is represented in the vast array of cutting edge developments in efficiency and practicality that permeate throughout the product ranges. From AGCO’s engines, which lead in fuel efficiency and reliability, and state-of-the-art dual fuel system, to a range of simple and enjoyable transmission units and articulated steering solutions, the Finnish company has not shied away from pushing the boundaries of the agricultural industry.

Demonstrating the effectiveness of Valtra’s commitment to customer service and innovation is its new T-Series tractor range. Launched in November 2014 and delivering its first vehicle a month later, the fourth generation T-Series tractor has reached record levels of sales for the company, with a full order book. The resulting machine is a product of extensive communication with customers over a five-year period before and during development. Over 40,000 hours of testing in all conditions have realised Valtra’s aims to produce a product that holds durability, high performance, low operating costs and driver

comfort as paramount to meets its customers’ needs.

The tractor is available in seven models ranging from 155 to 250hp from AGCO’s reliable 6.6L and 7.4L power units with SCR only, optimised turbo, EcoPower, SigmaPower and many other features contributing towards excellent fuel efficiency, low emissions and productivity.

Accompanying this are four transmission options to choose from to match every purpose and driver preference. The design of the tractor has revolved around creating a stylish, quiet and spacious environment with superior visibility, and driver comfort, ease of use, ergonomics and safety have been a top priority. The T-Series is also the only tractor to use AIRES+ pneumatic front axle suspensions providing unrivalled driving comfort.

Further indicating the success of the tractor is its receipt of the ‘Machine of the Year’ award, the most prestigious award in the industry, at the SIMA Show 2015. Recognising excellence in innovation, technology and total performance, Mikko Lehikoinen, Marketing Director at Valtra, said of the award: “This is an important recognition for Valtra and AGCO. We are

overwhelmed by the positive customer feedback, which we have received – this just proves that Valtra really has listened to customer needs and we have hit a jackpot this time with our new T4 Series.” The product also won the International Machinery Manufacturers Award for tractors at Cereals in June 2015, the same month that it delivered its 1000th T4 unit. Later in 2015, the company will be launching its new N-Series range, which the company hopes will replicate this success.

The way Valtra does business is summed up in its three-word promise: ‘Your working machine.’

By working closely with its customers across the world, the pioneering company is able to deliver the best, tailored solutions to its customer base and it is no surprise that it has secured such a reputable position in the market. Market conditions in the agricultural market on a global scale have been unfavourable and this has been reflected in the AGCO’s recent performance, however with new products developed from the same commitment to customer demand continue to enter the market, Valtra looks set to respond well as soon as the market springs back into favour.

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Frigoglass

Cool

runnings

Frigoglass is a leading player in the ice-cold merchandisers market and is also the most geographically diverse company within this sector, with operations spanning across 19 countries in five continents

Frigoglass Products: Commercial refrigeration and bottles Sites: Eight www.frigolass.com

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strategic partner to beverage brands throughout the world, Frigoglass has developed longstanding relationships with bluechip customers in the soft drinks and beverage industries thanks to its bespoke beverage coolers, which enhance its customers beverage branding and trigger beverage consumption. Today the global leader in the Ice Cold Merchandisers (ICM) market, and the principal supplier of glass packaging in West Africa, a high growth market, Frigoglass is also well-established in more mature European markets while it evolves into a burgeoning market champion.

Throughout its operations across the globe, the company maintains its market leading position thanks to its strong corporate values; these include integrity when conducting business, adherence to the most stringent quality standards and a commitment to the delivery of innovative and bespoke products that maximise cost-effectiveness. In addition, Frigoglass selects and develops its employees to ensure loyalty, commitment, professionalism and optimum performance when responding to and effectively solving customer requirements.

A firm believer that its people are behind its success as a business, Frigoglass strives to

foster an environment in which people are empowered to take ownership for outcomes while also working as a team. To help achieve targets, the company has five key principles for its employees: customer focus, quality, efficiency and competitiveness, innovation and a global yet local approach to projects.

In addition, Frigoglass’ competitive advantage stems from its broad geographic reach, its accumulation of blue-chip companies, its competitive cost structure and its after sales service; the latter of which includes maintenance, refurbishment and spare parts for all cold drink equipment. The company delivers its value-added service solutions to beverage companies in 48 countries; a feat that is managed through more than 200 service partners, one-to-one placement services in 12 countries and six refurbishment centres.

Also key to this coveted position in the ICM market is the company’s high quality products, which includes counter-tops and back of bar ICMs, open front and open top ICMs, single door ICMs and double door ICMs for Coca-Cola. The counter tops and back-of-bar ICMs offer a wide product display area with the product at eye level for the consumer, while open ICMs offer easy accessibility and flexible merchandising, making

them ideal for high traffic areas. Moreover, single door ICMs have an ideal footprint-to-volume ratio and provide strong product visibility; they are also considered a durable solution for all trade channels. Double door ICMS, meanwhile, are the ultimate solution for high consumption locations such as supermarkets as they offer increased capacity and impressive product visibility thanks to multiple facings; they also boast easy reloading solutions.

Within the latter’s product range is the Super 88 HC, which offers environmentally conscious customers an eco-friendly cooling solution thanks to its energy consumption of 7.4 kWh/day. The Super 88 HC also has an EasyFill sliding shelving system, a turnloader shelving system, visi-shelves and a door lock, while the branding includes an oversized canopy, price profiles with branded strips and a Coca-Cola contour bottle handle.

As the preferred supplier to Coca Cola, a massive 50 per cent of Frigoglass’ total revenue comes from this global leader in the beverage industry. With innovation an integral part of both organisations’ success, Frigoglass and Coca Cola worked on developing a unique drink cooler, which has resulted in the Coca Cola portfolio including ICOOL, a lower noise, low energy and

super efficient range of single door and double door ICMs. Created in response to changing market dynamics, ICOOL offers energy efficiency, new aesthetics, lower total cost of ownership and WiFi connectivity. In more detail, this includes a premium three-dimensional look, increased capacity and product visibility and strong brand identity; products within the ICOOL range are also easy to rebrand and upbrand. Products are also best-in-class when it comes to energy consumption, are maintenance free and easily serviceable, are relatively quiet and are connected and interactive.

The counter-top ICOOL range is comprised of ICOOL 40, ICOOL 150 and ICOOL 250, while the single door range comes in ICOOL 300, ICOOL 500 and ICOOL 800; Frigoglass features the ICOOL 1300. The ICOOL 300 offers energy savings of 57 per cent and a noise ratio of 55 dBA, while the ICOOL 800 offers energy savings of 19 per cent and has a noise ratio of 59 dBA and the ICOOL 1300 offers energy savings of 35 per cent and has a noise ratio of 61 dBA. Viewed as the next generation cool platform, the ICOOL range has been well received by Frigoglass’ customers across the globe and has cemented

Frigoglass’ position as a leader in innovation.

Another major customer of Frigoglass is Pepsi, for which the company offers a range of counter top and back of bar ICMs, open front and open top ICMS, single door ICMs and double door ICMS; the majority of which are eco-friendly cooling solutions.

As Frigoglass gains a new CEO in Nikos Mamoulis and celebrates its 20th anniversary of operations in Romania, its biggest production site, in 2015, the future looks positive for the company as it continues its focus on sustainable and profitable growth by capitalising on long-term market opportunities through innovation.

Optocore

“Optocore is a leading developer and manufacturer of energy efficient lighting technology, with global presence and specialisation in street, technical and refrigerator lighting.

“Frigoglass operates globally in a very competitive market and constantly challenges Optocore by seeking optimal solutions.

Optocore provides innovative custom products along with logistic operations and after sales services satisfying seamlessly any supply chain demand and every customer’s needs.

“Optocore’s know-how and field expertise led Frigoglass to choose Optocore as its trusted strategic supplier,” explained Dakis Poulantzas, CEO Optocore.

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A can-do attitude F Celebrating its centennial year in 2017, family firm Ferrum AG has become the global leader in the can seaming machine sector

Ferrum AG Products: Metal forming and sealing technology Site: Switzerland, US & India Employees: 420 www.ferrum.net

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ounded in 1917 as a foundry for machinery and special parts used in tintechnics facilities, Swiss firm Ferrum AG was taken over by entrepreneur Rudolf Werder in 1925 and has since grown from a young business with two business units - metal castings and machinery for the canning industry - to a 400 strong organisation with five companies of different sizes under its helm. “Our five different business units are foundry, manufacturing, centrifuge technology (pharma and salt winning sectors), canning and washing technology,” affirms Roger Küng, chief sales director of Ferrum AG’s washing machine sector.

“When the company was established, its main activity was the foundry and the manufacture of machinery and equipment for the canning industry. The division washing technology has been taken over in 1933 by the company Kienast and Lange. The washing technology was added as a 3rd division for Ferrum, producing washing machines, centrifuges and smoothness for large

laundries. Following this development, two more divisions were added: manufacturing and the centrifuge technology; the latter of which is used in the chemical, fine chemical and pharmaceutical industries.”

A firm believer that diversification is a successful core strategy, Ferrum AG is able to ride the waves of change as its markets have varied cyclic characteristics. For example, one market sector’s economic slump can be absorbed by the successes of other markets. Moreover, as Ferrum AG’s business units operate in small niche markets, they all boast significant market shares and are well positioned to maintain and expand these. “We supply a huge variety of industrial sectors with products and services that form the base for countless end user products. The widely diversified product range reduces the financial risks. Benefits of this include worldwide activities on every continent, a high level of self-financing and economic independence; all of which ensure that the company will continue to enjoy a strong

Ferrum

position with excellent prospects in the future.”

With offices in Rupperswill and Schafisheim, Switzerland, as well as Houston, Texas, the US, and Mumbai India, Ferrum AG has developed into a respected, financially solid company with a product and service portfolio that is tailored to the latest market requirements. Due to these strengths, the company has become the world number one in the can seaming machine sector and stands among the global leaders in centrifuge technology for chemicals, pharmaceuticals and raw materials. In addition, it is amongst the leading companies in Switzerland for car wash technology and textile washing technology and runs one of the bestequipped foundries in its home country. “Our canning technology is produced in Switzerland and exported worldwide; this is due to the strong reputation we have gained for experience and reliability over the last 98 years. Our canning machines can close 3000 tins in one minute. We also deliver, service, supply and install machines and spare parts across the globe,” says Roger. With well-trained and highly experienced Ferrum AG service employees working in 15 countries such as Europe, Asia, Russia and North America, the innovative firm is able to deploy products, services and staff to over 70 countries.

Proud to deliver Swiss quality and functionality in all areas of operation, the company’s canning technology sector has witnessed strong growth due to high quality machines with optimum productivity. In fact, a single can seamer can seam up to 150,000 beverage cans an hour on a nonstop, 24/7 basis. Moreover, to meet the special regulations for food processing technology, the company uses special vacuum seamer machines to seam wet products, such as corn, which increases the shelf life of the product.

Meanwhile, Ferrum AG’s washing technology business segment is the only division within the

company to not produce its own machines; instead, washing machines, dryers and ironers are directly imported from Belgium from the Alliance International. “The industrial ironing tables, small ironers and clothing distribution systems come from Sidi Mondial, GMP and LCT from the Netherlands, while installation and servicing comes from the Ferrum AG team,” says Roger.

“The market for laundry equipment in Switzerland is highly competitive. Many strong suppliers have very good quality machines on the market. The service takes more and more importance. Here lies the strength of Ferrum

washing technology. We are trying to stand out from the employees through an excellent service.

The importance of maintaining the service and supply of spare parts and equipment is very important. The customer expects a quick solution in case of problems or breakdowns. Replacement is only necessary, when the machine cannot be repaired. In these situations delivered must be quickly. We have very good experience with our suppliers, which is one of the main reasons why the business is going well.”

Benefiting from activities worldwide on every continent, a high level of self-financing and economic independence, Ferrum AG is certain to progress as an organisation with a strong market position, a broad product portfolio and excellent opportunities for growth. “We have a variety of interesting projects coming up in the future and, with this work load, are confident about the future.

Within the washing technology segment, we are looking to expand the business by 2018 and have more machines on the market; to reach this target we require good co-operation with suppliers and a strong connection with business partners,” concludes Roger.

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Lovink Technocast

Recast your mind Founded on a century old pedigree of innovation, Lovink Technocast is bringing iron casting technology into the 21st century

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ne hundred per cent owned by Royal Lovink Industries (a 104 year old group of companies with its headquarters and main production facility in Terborg,The Netherlands) Lovink Technocast is a foundry that manufactures metal castings through three distinctive foundry processes: DISA technology and moulding lines, lost foam and hand moulding.The high quality products from all three of these distinctive casting processes find their way to a global customer base in different industries.

Given its long history in the market - Lovink Technocast was founded in 1911 – it is no surprise that the company has established a position as a world leader with an exceptional global reputation.

As Alexander van den Hout (co-owner and managing director) explained, the company is known around the world for its quality, and also for the aesthetics of its products. “This has helped us to stay ahead because not every foundry can offer the options that we do,” he added before going on to highlight one of the organisation’s casting processes: “The lost foam method for example, gives us the ability to make spectacular and complex designs, which conventional casting processes would have to machine or assemble separately to achieve.”

Examples of lost foam castings include a turbo

Casting Lost Foam with integrated oil channels

As the examples mentioned above indicate, the automotive and hydraulics industries are very important to Lovink Technocast, with the majority of its lost foam customers coming from Europe and the US. “We create very complex products for those markets,” said Alexander. “We are able to take an old design that was made for a conventional casting processes with a lot of machining and assembly and, together with customers, redesign it using the lost foam process.

“In a process of co-creation with the customer we make it the best design possible. We support

Lovink Technocast BV Products: Iron casting technology Sites: One, The Netherlands www.lovink-technocast.com

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housing for a truck engine or a complex hydraulic component, with several internal oil passages. “I would say that lost foam gives the same freedom of design as 3D printing – where current technology does not allow us to actually undertake 3D print for larger products with metal economically,” adds Dirk Jan van den Hout (co-owner and managing director).

“Lost foam technology has all it needs to create high complexity castings at the right price and in batch sizes that are required by the customer. This strong and unique value proposition enables us to create a competitive edge. It puts us in a unique position that makes it possible to run a foundry in Western Europe.”

Casting conventional with machining

Left: Main picture: Lost foam casting Small picture: Pan support Below: Stove part

the customer in re-casting its mind and use the design freedom of lost foam technology to the full extent. Consequential benefits like lowest total cost of ownership and efficiency improvements in the product are passed on to the customer.The co-creation process between Lovink, the customer and possible other supply chain partners, allow all parties to improve their position on the market.”

Lovink Technocast has been working with lost foam technology for decades.

“During all these years we have been working on building up the knowledge and improving the process to the point that we are now. We are more or less leading from a knowledge point of view but it also means we can’t buy in knowledge, we have to develop it ourselves,” noted Dirk Jan. “As a result we have established strong relations with all of our key suppliers, and we depend on working closely together with companies such as Capital Refractories and Teubert Maschinenbau GmbH to improve our products and ourselves.”

Lovink Technocast has also worked with its supplier DISA since the 1970s, using two of its Disamatic automated greensand moulding lines with vertical sand blocks/moulds. Products from the two Disamatic production lines are mainly sold to the machinery, automotive and materials handling industries. A particular product for which Lovink has created its own unique position in the world of high end cooking appliances is cast enamelled cooker grates and burnercaps. It may not be surprising that the partnership with DISA Industries remains strong.

In April 2015 Lovink Technocast ordered a new DISA 270-A vertical moulding line. “The DISA partnership helps us to stay competitive long-term and increase our market share due to continuous implementation and improvement of new technology,” said Alexander.

It is clear that while Lovink Technocast already prides itself on its innovative processes, it is constantly striving to improve and ensure it is at the forefront of the market. “We are currently in the middle of a large investment around this new machine and optimised processes,” Dirk Jan said. “Our main focus is to make sure that we get the whole new process up and running and start using it. It will have quite a significant impact on this organisation and we have to make sure that both the company and our customers reap the benefits.”

As Lovink Technocast moves forward towards the future, its dedication to embracing upcoming technology shows no signs of waning and Alexander concluded with some predictions of what could be on the horizon: “In the coming years I think we will see that it will become easier to incorporate robots into the production process, and integrate these with digital information from the rest of the facility.

“I believe there are interesting times ahead for the whole industry. We will not only continue using new technology, we will also need to focus on adapting our business models. Business models that enable us to create sustainable value and thus maintain our competitive position. In the coming years we will be focusing our efforts on making sure we are one of the companies that can make the step and be ready for the future.”

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Zollern

Metal guru German headquartered family company Zollern has used its 300 years as a pioneer in the metal industry to become a global provider of innovative metal products

Zollern Products: Designs, produces sells and services metal products Sites: 22 www.zollern.de

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ounded in 1708 by Prince Meinrad II of Hohenzollern-Sigmaringen, Zollern today is the oldest family-owned company in the state of BadenWurttemberg, Germany. Headquartered in its founding location in Laucherthal, the company has spent the last 300 years developing its skills in areas such as plain bearing production, precision casting, the production of rods and bars and also gearbox production.

To further strengthen its services, Zollern made the strategic decision to acquire complementary businesses such as BHW Braunschweiger Huttenwerk GmbH, which had three plain bearings plants in Germany and Brazil in 1996; cutting metalworking firm Friedrich Blickle & Co GmbH and gearbox producer Dorstener Maschinenfabrik AG in 1999 and GMH Gleitlagerfabrik und MetallgieBerei GmbH, another plain bearings producer, in 2003.

Following this globalisation strategy, all companies during the takeover period began operating under the Zollern brand name in 2004. Further takeovers followed, alongside an investment of more than 100 million euros in the enhancement of operations through new processes and

technologies in 2006. One year on and these strategies proved themselves successful when Zollern broke the sales barrier of 500 million euros.

With more than 3300 highly dedicated employees in place to meet the needs of customers across the globe, the jewel in the company’s crown is its immense adaptability.

The group today consists of five business units, casting and forging technology, drive technology, bearing technology, steel profiles and engineering components, which means it is wholly capable of meeting the stringent demands of industries including automotive, aviation, construction, energy and power generation, machine building and ship, harbour and offshore.

Another part of the company’s globalisation strategy was to enable increased flexibility to its global customers. Understanding that each region and country has its own specific characteristics, Zollern established 15 production locations, branch offices and agencies in strategic positions around Europe, America and Asia.

By maintaining strong roots and expertise with a forward thinking approach to business activities, the family-owned company merges

customers in need of investment casting products made of steel, aluminium and nickel-cobalt based super alloys. This technique is generally used for small piece weights of between one gram and ten kilograms; larger workpieces of up to 150 kilograms are also possible.

The investment casting technique is characterised by an almost unlimited scope for the shaping of castings, minimum restrictions in terms of materials; a high degree of dimensional accuracy due to the elimination of the mould parting line, which tends to cause casting imprecision; facility for complex shaped inner contours due to ceramic cores utilisation, low material allowances on surfaces to be machined, and a high standard of surface quality. In fact, the investment casting technique is unrivalled in its scope for optimum shaping, which frequently makes it the solution for technical problems that would otherwise be impossible.

Zollern can also provide customers with oneoff productions as well as large-scale manufacture services within its sand castings production area thanks to its manual and machine moulding

methods. This versatility has led to the company being adept in its ability to cast demanding alloys and complex components. Production weights are between one kilogram and 8000 kilograms per piece of copper and copper alloys and between one kilograme and 1800 kilogrammes for steel.

Meanwhile, within its forging and rolling plant, Zollern produces forged copper and copper alloys with its forging hammers and a hydraulic forging press that operates at forces of up to 1600 tonnes. This production process transforms the formerly coarse grained cast microstructure into a fine grained structure, which increases its strength values while maintaining tenacity and ductility. Forging also increases the density of the material, which ensures high operating reliability under high pressure-related stress and during vacuum applications.

With a strong history behind it, the wellreputed Zollern can move forward with confidence as it continues to integrate tradition with innovation to meet the needs of its wide ranging customer base.

tradition with innovation to create optimum solutions for customers. One prime example of this can be seen in its casting and forging technology business segment, which first began in 1890 when Zollern’s bronze foundry went into operation. More than 120 years of experience has remained within the casting and forging technology segment, however, as expected, the company has also enhanced its capabilities in line with market demand and become one of the few organisations able to offer both cast and forged copper and copper alloys. Having helped shaped every stage every stage in the development of casting and forging technology, Zollern is now widely seen as not only one of the leading names in Europe, but is also a well respected exporter to some of the major industrial organisations in the world.

Within this area of the business Zollern can offer customers forging and rolling services, sand casting and investment casting; the latter of which it began more than 50 years ago. As this precision casting method continues to become increasingly economically important on an international scale, the company is in an enviable position as it has the know-how and equipment to provide

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Tandom Metallurgical Group

Strides

ahead

Unprecedented levels of growth define the short history for Tandom as it leads the way in an expanding and ever-diversifying market

Tandom Metallurgical Group Ltd Products: The UK’s industry leading provider of metal recycling Sites: Cheshire and Birmingham, UK www.tandom.co.uk

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aving been founded in 2008 from the merging of AL Resources Ltd and Integrali Ltd, both successful trading companies dealing in all grades of ferrous and non-ferrous scraps, and later Chinook Sciences LLC, Tandom has experienced unprecedented levels of growth to become an industry leader.

Dealing in the processing tolling and trading of recycled metal, the company offers a whole range of processes for aluminium, used drink cans, ferrous and non-ferrous scrap, drosses and stainless steel applications. Indicating the level of growth earned by the company, Tandom has grown from 10 to 85 employees since its establishment and currently forecasts to turnover £70 million in its seventh year, £30 million of which is to export markets. It has also featured regularly in the Sunday Times Fast Track and International Track, for the fastest growing companies in overseas sales, and achieved the number one spot for the latter in 2014.

Tandom has an extensive offering of services when it comes to its recycling capabilities, namely: melting, shredding, baling, toll conversion and factory clearance. However as Managing Director, Tom Muir explains, it is not solely the recycling that has rewarded the company with its success but its diversification within the sector.

“This diversification takes the form of supplying recycled die-casting alloys to the automotive industry, processing used aluminium beverage cans for recycling and processing copper bearing scrap and stainless steel scraps mainly for export

to continental Europe, China and India,” he says.

“We also produce specialist alloys for use in the primary aluminium sector as well as offering a toll melting facility to other metal melting companies whereby we recover metal from their furnace residue, which could otherwise be consigned for landfill.” With such an extensive range of processes in place, a diverse range of machinery with the capabilities to melt, blend and recycle materials has been brought into the company’s facilities.

Current market conditions are partly responsible for Tandom’s considerable few years as the manufacturing industry becomes increasingly aware of the need to recycle and the benefits associated with using recycled material, and there has been a particular surge of demand in the aluminium sector. As such, the company has processed over 50,000 tonnes of metal over the last 12 months. “Although it has required a great deal of investment in terms of plant and processing equipment this diversification provides us with some degree of protection from the vagrancies of each individual sector, for example the downturn in automotive production in 2008/2009,” expresses Tom. “In this way we hope to maintain a steady level of growth in terms of turnover and profitability over the coming years whilst minimising the risks associated with any downturn within any of the individual sectors.”

Whilst adopting this strategy has been central to Tandom achieving the levels of recent growth, perhaps even more core is the level of experience supplied to it by its level of in-house

expertise. “The key to the success of this strategy is very much down to the people,” outlines Tom. “We have a team of people with great expertise and many years’ experience in each of the sectors in which we operate. These are people who are very well known and very much respected within the industry. This experience and expertise is very important to us in terms of giving confidence to our trading partners and customers when dealing with Tandom.”

Based on the rapidly earned success that precedes it, the future for Tandom looks bright.

“All in all we are very happy with what we have achieved in the few short years since the company’s inception but even more importantly we are very excited by the possibilities of more of the same over the coming years,” says Tom. “We have very recently obtained planning permission to develop our recently acquired four acre site, which adjoins to our existing Congleton site. Whilst there will be no actual production here, it will allow us to expand our metal trading activities in the North West to hopefully replicate the success of our Birmingham trading operation in terms of export sales.”

By continuing to take advantage of the indepth knowledge and specialist facilities present at Tandom, the company is in a strong position to extend its lead in the market. Combine this with its dedication to quality product, service and unrivalled growth, and it is clear that Tandom is taking positive strides on the path to success. “Our aim is to be recognised not only as an efficient, well-run company but also as a trustworthy and honourable one. For example we want other companies to be able to do business with us safe in the knowledge that we are fully aware of our health, safety and environmental responsibilities, which will not be compromised in any way for commercial or

financial considerations,” concludes Tom. “To this end we have been, and still are, investing heavily in the latest furnace and environmental equipment to keep Tandom at the forefront of, and up to date with all, current and foreseeable environmental legislation.

“While we are not quite there yet we are

well on the way to achieving the original vision of Tandom, which is to become one of the most modern, efficient and respected recycling organisations within the UK.”

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Burgess Furniture

Built to

last

Having established a world leading position in the hospitality market, Burgess Furniture continues to innovate and meet customer demand to expand into an ever-growing industry

Burgess Furniture Ltd Products: Specialises in manufacturing steel and aluminium tables and chairs, including soft seating ranges and accessories Sites: Four www.burgessfurniture.com

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n 1959 Gerald Burgess was approached to make stacking aluminium chairs for the Mayfair and Metropole Hotel in Monte Carlo. The company’s first order was for 1000 chairs, half of which were to be exported to Monaco, and what followed was a long history of success founded on the core values of innovation, quality and value for money. Since then Burgess Furniture has supplied to some of the most prestigious venues around the world and now exports to over 50 countries every year.

“Burgess has a very clear focus and that is hospitality,” begins Sales and Marketing Director, Simon Richards as he outlines the company’s client base. “We focus very much on the hotel market, for conference and meeting rooms, as well as banquet furniture and we supply all the main brands such as Marriott, Radisson, Hilton, Starwood, Accor, InterContinental and so on.

We are also the brand of choice for many other businesses that have a need for seating and tables such as exhibition centres, training and meeting companies, and sports facilities like Wembley, Cardiff Millennium, Kempton Park, Sandown and Ascot.”

‘Innovation, Quality and Value for Money’, is the company’s strap line and is an ethos adopted across the business. “This sums up why we continue to be the leader in our market,” says Simon. “We spend a lot of time developing products in conjunction with our customers so

they get exactly what they need. Also because we are a manufacturer and not just a component assembler we are able to be very flexible in our approach to requests from our customers. We continue to invest heavily in design and machinery in order to maintain our competitive edge and offer the best value.”

Amongst its extensive range of chairs, tables & accessories, Burgess’s portfolio features some iconic and hugely successful products. Simon highlights some of the most popular from the company’s history: “The Turni was the very first chair the company made and has changed very little over the years; 56 years on people still want to buy it which is amazing.” In recent years Burgess has also launched the Vario, Orvia and Mendola ranges, which have all proved to be very popular.

All three are designed withfuncionality, comfort and lightness in mind. “The Mendola takes on board one of the latest innovations in seating, which is Probax,” he details. “This is a very clever system of foam inserts of specific geometric design, which leads to a much improved seating position for the user, giving greater comfort and posture. A highly comfortable seat is a major selling point for any venue.”

One of the company’s most recent successes is the Evosa range of chairs, which was launched in May 2015. “The reaction to this new range has been amazing,” expresses Simon. “It has a very slim chromed base and can be supplied as

a seat stacking or frame stacking chair. Its unique construction has meant we have taken a large amount of weight out of the chair. Lightweight products are a real selling point, as any operator moving 400-500 chairs on a daily basis will tell you.

It’s this design and innovation that I believe sets us apart from others in the market.”

Another exciting new development from Burgess is the soft seating range, for a more relaxed offering. “More and more hotels require meeting and breakout space that is flexible,” explains Simon. “Of course they still want the traditional meeting tables and chairs but they also want the flexible relaxed meeting space as well. We are starting to see these products used front of house and in hotel bedrooms as well, particularly in hotels with a more contemporary design.”

Current activity for Burgess illustrates a continued enjoyment of growth and success with a number of new contracts developing with major hotel chains. One particular area that is seeing major growth at the moment is the Middle East, and the company has now established a showroom in Dubai. As Simon highlights: “The Middle East and Africa are the major growth markets for the next few years judging by the number of hotel projects that have been announced. The reaction to this move has been excellent and we are getting hoteliers and owners come along to see the range of products we offer on a daily basis.”

The company’s global spread is growing all the time. With a joint manufacturing venture in the US, which caters for the American market, and opportunities emerging in the Eurozone as it leaves the recession behind, Simon is confident that this is only set to continue. “Our aim is and always has been to maximise our potential,” he concludes.

“We have some great customers and some great products. We will therefore continue to develop and innovate in our designs, keep our customer service at the highest level and focus our resources on growing markets as we move forward. To achieve this we will also carry on investing in our people and our production facility.”

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Ekamant

A

polished

offering

Bringing a tradition of innovation together with modern technology has enabled Swedish company Ekamant to occupy a leading global position in the abrasive market

Ekamant AB Products: Leading specialists in coated abrasives for the wood industry Sites: Five www.ekamant.com

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kamant is currently one of the world’s leading producers of coated abrasives for the wood industry. Founded in the Swedish forests back in 1928, the company has grown solidly through a programme of continuous improvement and innovation to establish a wide range of products suitable for a variety of applications. “The company has a history of introducing groundbreaking coating abrasive technology,” begins CEO, Mikael Rietz. “Today, we serve more than 60 countries globally with all kinds of abrasive products and are still expanding our global footprint every year.”

The core strength for the Swedish firm is its consistent focus on innovation. “Throughout our history we have tried, tested, failed and eventually succeeded with our products,” continues Mikael.

“However, the goal has always been the same: to find ways of making our products even better and more effective in supporting our customers’ development. Our combination of tradition and high technology is unique and it has inspired us to think outside of the box and use abrasives in an innovative way for the benefit of both present and future generations.”

An overview of the company’s product milestones goes some way to illustrating this approach in action. In 1953 Ekamant adopted an electrostatic coating method in manufacturing and three years later it developed its first resin-bonded

abrasive paper. In the seventies, the company had its first patent awarded for antistatic abrasives and later on launched Antistatex – the first antistatic abrasive paper in the world. This tradition continued in the eighties as Ekamant responded to customer demands by introducing a range of phenolic resin-bonded coated abrasives, which demonstrated much improved durability. More recently, in 2008 the company looked outside of its established wood market and began offering solutions to the metal, automotive and composites industries.

“We are continuously developing our products and adapting them to the market and our customers’ needs,” notes Mikael. As a result of such a history, today’s product offering can be defined by quality and durability as well as being supported by outstanding technical support and service delivered by a globally integrated distribution network.

Today, the company’s portfolio encompasses a whole range of solutions for wood, metal, automotive and composite applications. From wood shaping and sanding, to aluminium and lacquer polishing, Ekamant’s products are available in a variety of belt, sheet, grinder disc and roll offerings. In addition to this standard offering and in keeping with its continuous drive for innovation, the company has developed abrasive brush products, finishing concepts for polishing

applications, foam backed abrasives, machine accessories to accompany the standard range, and a non-woven product for cleaning and polishing purposes called EKA-BRITE. The company currently operates from its main operational site in Sweden, which it has upgraded this year to meet higher demands from the market.

However, as Mikael explains: “Our strategy is to make customer orientated products by fine tuning standard products to customer needs in our conversion plants around the world.” In order to ensure its products meet exacting standards across the company, Ekamant has established synergies between modern technology, highly skilled employees and strictly regulated raw materials to guarantee the highest quality is maintained from material to finished product. “It is very important for us to work in close co-operation with our suppliers,” notes Mikael. “Daily contact as well as general updates with the suppliers is an ongoing process.”

The market for Ekamant at the moment is positive. Mikael expresses some awareness to particular challenges facing the industry as a whole.

“We are seeing more and more low cost products with increasing levels of quality coming into the market,” he says. “However I believe there is still a lot of opportunity for us to continue delivering high quality materials combined with good service to our distributors and end customers.”

In accordance with its tradition for innovation and product development, Mikael notes that the next 12 months will see a continued focused on developing new products and services. “As well as this, we will be looking at maintaining efficient development of our processes to meet our customers increasing demands,” he adds.

“We have experienced stable growth over the

last few years and as we move forward we will keep our focus on growing organically, market by market. We believe in delivering high levels of service alongside good and stable products

to the customer to support their business.

Strong collaboration with selected partners is an effective way of developing the service and product offering to the market.”

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Hitzinger

Increasing the

power

With nearly 70 years of experience in tailored power supplies, Hitzinger is a market leader in the provision of alternators, gensets, converters, UPS systems and aircraft ground power supplies

Hitzinger Products: Alternators, gensets, converters, UPS systems and aircraft ground power supplies Sites: Austria, the UK, Singapore, Florida www.hitzinger.at/en

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ounded in 1946 by Walter Hitzinger and Hans Schaeke with the goal of specialising in the manufacture of rotary alternators for the re-building of train networks during the World War II, Hitzinger GmbH has since extended its product range to include other sectors of rotary equipment such as rotary diesel UPS, diesel gensets, frequency converters and airport ground power. Based in Linz, Austria, where approximately 260 employees work across three production plants and five production lines, the company strives to deliver innovations through the continuous further development of its core competencies. In addition to its headquarters, the company also has subsidiaries in the UK, Singapore, and Florida, the US. Discussing the company’s product range is Werner Haas, Managing Director of Hitzinger: “Our core product is the electrical machine, most notably the alternators and our main competence is in developing or engineering customised alternators for special purposes; we have no mass production. The three main markets for our alternator business are hydropower, up to four MW, traction alternators for rail applications and auxiliary power supplies for ships; this part of the business takes up approximately 30 per cent of our overall turnover.

“Our next product range is for airport technology; within this business segment we engineer, design and produce power supplies for airplanes that are always landed and in position.

The products for this segment are called ground

power units (GPUs) and we have D Power mobile GPUs, Jet Power mobile GPUs and Mil Power mobile GPUs. This is a niche market in the industry as the frequency is completely different to the main frequency of the power supply.”

With the D Power, Hitzinger presents its customers with a new brand of ground power supply for their aircraft during the flight preparation phase. Benefits of choosing D Power include increased efficiency, total cost of ownership reduction and user friendliness. Moreover, it is characterised by optimised economy and increased efficiency, offers low maintenance and is extremely easy to service and operate, making optimum power a guarantee. The little sister of the D Power is Jet Power; offering the same benefits of D Power, the Jet Power is also focused on achieving the lowest fuel consumption and sound level and achieves impressive compactness through an appealing design and ergonomically arranged control panels.

Last but by no means least is MIL Power. Trusted by armies and special forces across the globe, Hitzinger’s MIL Power is the result of collaborating with leading militaries to ensure it is able to handle the most demanding conditions of military use.

Boasting robustness and longevity, as well as the lowest fuel consumption and jet fuel compatibility, MIL Power also offers suitability with optimum dimensions, low weight, a low sound level and an innovative EMC concept.

In addition to alternators and GPUs, the company also creates UPS systems for data centres or industrial companies that need

blue chip organisations such as the British Navy, as Werner highlights: “We are equipping the Type 23 Frigates with converters and alternators as part of a refurbishment project.” Following the UK MoD’s decision to award contracts worth £80 million for the upgrading of the Type 23 Frigates, each ship will be supplied with four new diesel generators and associated power distribution. Meanwhile, a second contract with Hitzinger involves the provision of voltage converters that will ensure increased power on the Frigates. The equipment is to be installed at Her Majesty’s Naval Base in Devonport and is anticipated to be complete in 2024.

Moving forward, Hitzinger aims to increase

turnover over the next five years, with growth expected especially within its UPS systems product range. “We see a very good market for these products in the future, not just for data centres, but also hospitals and similar applications. To do this we want to increase the electrical power for each individual machine; we currently have 2500 kVA but would like to move up to 3000 kVA or even more. However, this is just one corner stone of our development programme, we also want to add products to our airport technology segment and generally have more products within our whole portfolio so we can grow in all areas of the business,” Werner concludes.

emergency power in case of a failure in power supply. Comprised of five major components, the diesel engine, the electromagnetic clutch, the synchronous alternator, the kinetic energy storage module and the coupling choke, Hitzinger’s UPS systems offer the perfect match for its clients’ needs by completely designing and developing solutions in-house.

As a customer-orientated organisation with a firm belief that innovative concepts and designs are at the core of all company developments, Hitzinger focuses on finding bespoke solutions that are specific to the challenges of its customers. To do this, the company has a team of highly experienced and well-qualified engineers and designers that are dedicated to creating solutions that merge maximum efficiency with optimum flexibility.

Indeed, by continuously finding ways to increase the efficiency of its alternators and convertors, while also optimising the amount of fuel consumed by its ground power supplies, Hitzinger remains a pioneer in meeting the needs of those within its customer base while also keeping pace with market trends and demands.

“We are very customer focused,” confirms Werner. “We are not producing parts for stock so everything we develop and produce is specifically for our customers. Because of this, we tend to focus on efficiency and total cost of ownership as well as low diesel fuel and low power loss; these are our strengths.”

These strengths have not gone unnoticed in the market, with Hitzinger gaining contracts with major

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Step-Tec

Intelligentvision Today Step-Tec AG occupies a leading position in the market because of a dedicated commitment to innovation and customer service

Step-Tec AG Products: Specialist in the design, production and repair of high quality motor spindles www.step-tec.ch

Above: The founders on Step-Tec’s 20th anniversary

‘‘S

tep-Tec has been developing, producing and servicing Swiss quality spindles for mould making, production and aerospace since 1995,” begins Fabrice Monti di Sopra, MD at Step-Tec AG. “The company’s sole focus is on providing its customers with the best solutions with the aim for the lowest total cost of ownership (TCO) and as such describes itself as a solution provider, rather than a product manufacturer.”

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With this commitment lived by a dedicated team along with a clear vision of innovation, Step-Tec has taken the lead in the global market of motor spindles. Based in Luterbach, Switzerland, Step-Tec’s manpower accounts to about 100, generating an annual turnover between 30 million to 40 million Swiss Francs. “By the end of 2014 we had manufactured and delivered well over 20,000 motor spindles and refurbished an equal number of spindles that receive a second or third life, ” explains Fabrice. “Today, working in close co-operation with our customers and their needs, we build some 80 different high precision-/ high performance spindle variants with diameters starting from 90mm to 320mm covering a power range from 1kW up to 82kW.” The current market for high precision and high performance motor spindles is a strong one, especially in Europe and Asia, where significant growth could be seen in recent years.

Step-Tec is ideally positioned to participate in this global market. “In the premium segment of high-precision- and high-performance motor spindles, there are only few players really owning and mastering the required expertise. I am proud to say that Step-Tec has been able to maintain a leading role over two decades,” adds Fabrice. As such, the company’s products are currently installed in machine tools of 70 different companies around the globe and are served by a worldwide network of service centres with three main hubs, naturally the one in Switzerland but North America and China as well.

To occupy and hold this leading position, Step-Tec’s products and services have to be of the highest quality in its pursuit of providing the best TCO in the market as Fabrice declares the essentials for accomplishing a leading position that are these three key factors: “Firstly, we are a unique ‘all-in-house’ supplier specialised in mechatronics covering all operations and processes as to name the relevant ones like engineering, followed by the production and customer services,” he says.

“Secondly, our employees here form a highly

motivated team personifying values like dedication, pride, specialised skills not found elsewhere along with yearlong experience all embedded in an open environment with a flat leadership structure.

This is insured by providing continuous in-house training as well as close collaboration with external engineering pools and universities to constantly upgrade and enhance our products to meet the current state of the art technology standards.

“Finally, Step-Tec’s sub suppliers need to be reliable, on-time, quality-orientated and cost competitive. We are happy to confirm that we have excellent, co-operative and trustful relationships with our main suppliers, some of which have been with us from the day of founding Step-Tec. “Innovation is what drives us to contribute to the company’s success as this is evident and a result of the ever on-going product development.”

Step-Tec’s product range focuses predominantly on three target areas of applications: mould and die, production, and aerospace/energy. Fabrice is keen to point to two major and recent innovations of which the well-established intelliSTEP system holds more potential for future utilisation as part of the machining process optimisation while even going as far as to offer preventive maintenance.

“Already today Step-Tec spindles are equipped with displacement- and various temperature sensors and a patented 3D vibration sensor for real time monitoring,” he notes. “This information can be used for the milling management (similar to the motor management of a race car) for improving the machining process as well as the machining quality. As for the other more recent innovation the signals from the built-in 3D vibration sensor serve the MSP. The Machine and Spindle protection features as an option in a machine tool to protect the spindle from permanent damage in case of a collision. It not only saves the spindle from being replaced it saves the machine’s geometry and again further reduces the TCO during the life time of a machine tool.”

The built-in spindle diagnostic module SDM

enables field service technicians online access to the spindle through the SDS diagnosis software.

The various spindle parameters including crash events can be utilised by the machine’s CNC control for the purpose of optimising the machining process. The digital spindle is just a step away as the full benefit shall reward the customer by again reducing his TCO while increasing the overall performance and machining quality of his machine tool at the same time.

An earlier major step forward had been the introduction of the Cool-Core spindle that delivered the solution to one of the main challenges of precision machining - high temperature conduction into the rotating spindle shaft coming from the tool. “We have developed a spindle that resolves the temperature issue at the point of origin,” highlights Fabrice. “This spindle, yet being offered as a platform spindle with a variety of features and power holds this already approved unique cooling concept, cooling both stationary and rotating parts of the spindle to minimise the thermal growth towards the work piece while at the same time reducing the heat transfer to surrounding machine components. This results in the best possible thermal stability of the entire spindle setup in the machine support ensuring enhanced machining accuracy & surface finish by the least amount of thermal growth, the key and solution in high precision milling.”

Continuing to add value, sensing customers’ needs and living a culture of open co-operation are central to Step-Tec’s vision and values. “We have some exciting developments in our pipeline that will be revealed in the next few months, which will further enhance machining accuracy and surface finish in the mould and die segment,” Fabrice concludes. “In addition we plan to significantly widen our service portfolio so as to further promote it worldwide, including preventive maintenance activities that will significantly benefit our customers by lowering their TCO. In the long term, we will be looking to strengthen our activities in Korea, Taiwan and China as well as pushing forward our innovations to pack more intelligence into our spindles.”

Top left and right: Sophisticated sensor systems allows measurement of ‘crash-intensity’ and subsequently spindle damage Right: A Step-Tec spindle Bottom right: Assembling a spindle

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Summitglow

Hardened

success

A wide market spread allows Summitglow to alleviate industry pressures and with a service offering growing all the time, the company is in a strong position to secure further expansion

Summitglow Ltd Products: Specialists in steel heat treatment Sites: Two www.summitglow.co.uk

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ased in Sheffield, Summitglow started out in 1983 providing salt bath heat treatment services to the buoyant local cutting tool industry. Through a steady process of expansion, today’s family-owned company has diversified into a range of markets, offering an array of different treatment services with a consistent focus on delivering the highest quality. By balancing a use of both traditional and cutting edge technologies, the 25-strong team at Summitglow has developed a reputation for delivering unique and specialist treatment services.

The capabilities of Summitglow currently include: vacuum, salt bath, case hardening, gas nitriding and nitrocaburising, sub-zero (cryogenic) and air and atmosphere treatments, as well as hot chemical blacking and straightening services.

“The main strengths of the company are our continued focus on delivering very fast turnaround times and being very diverse,” begins Managing Director, Philip Watkinson. “We serve the hand tool and wood turning tool, medical and automotive markets, all of which are presently relatively strong. However, the one market that is really challenging at the moment is oil and gas.”

Philip expresses that the widespread effect of the oil and gas industry’s downturn is underestimated.

He notes that its ripple effect can be felt much further down the supply chain than the immediate suppliers and this is making it very difficult for companies that have focused solely on this market.

“It has always been a clear strategy for us not to focus too heavily on any one market for this reason,” he continues. “Therefore, strength in other markets allows us to balance out downturns in others.”

In accordance with this strategy Summitglow continuously invests into new capabilities to open new markets and opportunities. Most recently, the company has taken delivery of a new Ipsen half-tonne capacity vacuum furnace to expand its capacity. “We have offered this treatment for about 15 years with a small furnace designed purely around doing small batches with rapid turnaround,” explains Philip. “Whilst this will still remain a core offering of ours, this new furnace will allow us to carry out larger batches of work as well and thus open up new markets for us. The investment started at the beginning of last year when we put a new power supply in, again to facilitate further expansion, and the new equipment has the capability to deliver six-bar pressure quench and high vacuum applications to treat a wide range of materials.”

Below: Ipsen VTC vacuum Right: Micro Macro tester Far right: Salt bath

with products manufactured overseas, therefore we will continue offering what we do and we will continue developing these services.”

Over the next 12 months, Summitglow will be looking closely at the opportunities opened up by the new furnace as well as maintaining its already established capabilities. “The vision is, and has been for a while, to progress further into doing more high-end, highcomplexity components that require high

tolerances and better quality. By pushing for higher technology, higher quality, high-end markets, whilst maintaining our spread of markets, we will be able to continue to grow,” concludes Philip.

Other recent investments include a revamped website, which Philip reports has been successful in generating more enquiries and continuous developments to the company’s salt bath treatments. “There is still a large, specialist demand for partial immersion, neutral salt bath treatments within the craft tool and aerospace industries,” he says. “This is because it is a very effective, repeatable way of treating only parts of a component, which can’t be done in a vacuum furnace, and it delivers consistently high quality components. Over the last few years we have invested in upgrading a lot of this technology to yield greater performance in terms of energy efficiency on those lines.”

Quality is paramount for Summitglow and as such the company has ISO 9001 accreditation and implements QS9000 into its working practices.

Enhancing its range of services are the company’s comprehensive testing facilities, which include Rockwell, Brinell, Vickers, Micro Vickers and portable hardness testing equipment to ensure quality is maintained. Many of its offerings provide a level of service capability beyond what is currently still available elsewhere in the market. For instance, as Philip highlights: “We can still gas nitride up to four metres in length, which is useful for a lot of markets like extrusion and oil and gas, but there are not a lot of companies still offering this. I think what we do remains a critical part of the market as it is in heat treatment where many issues can arise

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Brüsch Precision

Quality is

key

Brüsch Precision AS is one of the world’s leading developers and manufacturers of precision components for industries such as medical technology, defence, scientific research and energy

Brüsch Precision AS Products: Precision components Sites: Rødovre, Denmark www.brusch.dk

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amily owned for three generations, Brüsch Precision A/S is a financially stable organisation that boasts many years within the machining sector and a wide range of blue chip companies as customers within industries where precision and quality are imperative. “Since our foundation by Hermann Brüsch, grandfather of myself, Jakob Brüsch, in 1958, we have been in constant development,” begins Joint Owner and Managing Director Jakob Brüsch. “Over the years focus has changed from mass production of standard parts to the production of more complicate parts for more demanding customers. At present we have 35 employees working three shifts on a 24/7 basis and 75 per cent of our turnover comes from exports to Norway, the US, Australia, Germany, Slovakia and Ireland.”

Processes undertaken by Brüsch Precision include CNC turning, which enables the firm to supply workpieces up to 0200; within this business segment it works with all materials in batch sizes from ten to 5000 units. The company also boasts CNC sliding head turning machines, which deliver precision workpieces in all materials up to the dimension 032; batch sizes range from ten to 10,000 units. On top of this, from its state-ofthe-art CNC machining centres, the company supplies workpieces in various sizes and works with all materials in batch sizes from 50 to 5000 units. Discussing current projects, Jakob notes: “We are very proud to be supplying parts for space

projects. In 2016 the final project will be finished and sent to ISS for installation on the Columbus Module. We also produce parts for complicated surgeries, which save lives and also increase the quality of patients’ lives. Although we have NDA with most of our clients, many of them are highly recognised, well-established market leaders in their own fields.”

Operating within markets that all have confidence and high demands in quality, precision and flexibility, Brüsch Precision has honed its expertise in these required areas to ensure optimum satisfaction, as Jakob highlights: “We have worked with quality systems since the late 1970s and the quality throughout our corporation is in all of our cells – we are quality. We have ISO 13485, a quality system regarding medical devices, which is extremely important to most medical device manufacturers. In fact, when this standard is mentioned doors are almost opening automatically. On top of this, we are also interested in delivering low volume parts, an area that is not very common. To maintain our good reputation for competence, we train our employees to be highly skilled, responsible and humble towards every single assignment they work on. At Brüsch Precision we take great responsibility in educating and supporting young students and always have at least three students progressing in-house.”

By preventing a shortage of skills within its areas of operation, Brüsch Precision will always be

prepared to meet the demands of its clients in its core market industries. “The industrial technicians that we educate are trained in meeting the high demands that are found in the segments that we address. We have several students that have been picked to compete in industry-specific competitions and have won. Indeed, to educate and support young people is one of our declared CSR strategies and we are very proud of it!” adds Jakob.

Alongside this focus on quality in all areas of operation, the ISO 9001: 2008 certified Brüsch Precision also has its own quality department, which further guarantees consistent high quality through complete process control and individual quality solutions in accordance with customer specifications. By living and breathing quality throughout the entire process, the company offers zero defects during production, an individual quality process, complete traceability, documentation for all processes and certificates for materials and processes.

Once the products have been manufactured, the company offers whole or partial assembly as well as purchasing and stocking of subcomponents for fitting to workpieces. Meanwhile, the final check, as well as documentation and packing, are completed as agreed with the client. For the delivery of products, Brüsch Precision offers customer specific packing and shipping and will also willingly send directly to business partners across the globe. All items that are sent from Brüsch Precision are given a final thorough check to ensure the agreed level of quality is guaranteed.

Individual traceability is also offered in addition to shipping solutions.

With 75 per cent of turnover coming from exports, moving forward, Brüsch Precision is looking to develop the German market over

the next six to 12 months, as Jakob states: “We have identified 700 potential customers within the medtec sector; 70 of which we have called directly and are currently planning visits to. The initial call and following contact has been performed by an agent and our local representative in Germany.

Once we have built up a customer base in

Germany, we will consider starting the same project in the UK and Ireland.”

On top of this, the quality conscious company will naturally continue to improve its quality system and create methods to maintain its position as a globally leading manufacturer of precision engineering components.

Titanium Gateway Titanium Gateway is a modern stockholder and supplier of titanium and special alloys within sectors such as medical, energy, science and defence. It is proud to be a key material supplier for Brüsch Precision and to contribute to their market success.

The company shares the view that all customers are unique, and its mission is to exceed the expectations of every customer.

This is made possible by quick responses, fast deliveries, high quality and a flexible material solution. .

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friedola TECH

Packaged for

success By paying constant attention to quality and innovation friedola TECH’s progress in the market is taking significant strides as demand increases

friedola TECH GmbH Products: Manufactures customised plastic solutions Sites: Four www.friedola-tech.de

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F

ounded in 1990 following the development of its innovative CON-Pearl® technology 18 years prior, friedola® TECH has a perfectly positioned portfolio to serve growing trends in the packaging and automotive industries.

With markets established in Europe and the United States from production sites in both, the company’s core offering revolves around two central brands, CON-Pearl and CONCoverTM. CON-Cover is a robust textile covered plastic moulded range of parts used mainly in

automotive applications and is available in bi- and tri-laminate solutions. CON-Pearl is the most important product for the company and in its simplest form is a laminated lightweight board with high levels of strength and reliability, used in a range of packaging and automotive applications.

“Our main strengths are that we produce very high quality products as well as having a reputation for being reliable with very good customer service,” explains CEO, Dr. Matthias Stein. “Our innovation potential is very important and we are constantly developing new features and product solutions by working closely with our customers to solve problems and develop new applications.”

Fuelling these strengths towards continued growth and success is a couple of growing trends in both of friedola TECH’s key markets. “In the automotive, light commercial vehicle (LCV) industry, it is becoming more and more about lightweight solutions in the substitution of wood,” continues Matthias. “This plays into our hands as our CON-Pearl solutions are perfect for this and the LCV market is in very good shape at the moment. In terms of packaging there is a growing trend towards multi-way packaging, as reusability becomes more popular and more compliant, so we see good opportunities for us with our collapsible and robust packaging solutions.”

The centrepiece for friedola TECH is CONPearl. The lightweight boards, which consist of three laminated polypropylene layers, the middle of which obtains a special thermo formed structure, are 100 per cent recyclable and are

perfectly suited for a range of applications.

For example, the company markets a range of collapsible and reusable packaging solutions, as well as load floor, side wall covers, trunk floors and moulded parts for automotive applications. As Matthias previously mentioned, innovation is key to maintaining continuous development within the product range and a team of four executives regularly meet to assess market demands and ideas, and implement strategic steps. “We also hold regular innovation workshops with our employees where we look at new materials, and at our strengths and weaknesses to see where we can improve,” he notes.

Central to CON-Pearl’s development is its strength. In May 2015, the company announced that its new load floor solutions had increased in load capacity strength by 100 per cent making the resulting material comparable in strength to that of wooden floors. This was accompanied by three variations: the Safestep, a non-slip solution for high degrees of occupational safety and efficient transportation solutions; the Strong, which utilises a special, highly resilient polypropylene-fabric to increase its resilience; and

the Allround, which makes it suitable for a range of applications. “All of our load floors still have the features that are being appreciated by the market,” says Matthias. “These are the low weight and thus lowered fuel consumption, as well as

the easy installation, aesthetic appearance, easy cleaning possibilities and resistance to possible mould and rotting.” In addition to this, the company has also developed a range of solutions for the packaging industry including a collapsible

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friedola TECH

‘‘

Our innovation potential is very important and we are constantly developing new features and product solutions by working closely with our customers to solve problems and develop new applications application that maintains internal climate.

In order to maintain its quality offering, friedola TECH prides itself on its complete production capabilities as it manages an entire value chain

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from recycling raw materials to the end product.

“We have a plastic recycling plant in Leinefelde, which was acquired in 2000,” outlines Matthias.

“We also have the facilities to extrude, laminate, stamp and post-process all our products here in Geismar. Last year we invested into a brand new lamination machine and we have also recently invested into our recycling plant and foil plants. These investments have allowed us to keep up with capacity enlargement, stabilise our production line and improve product quality.”

Continuing its trend for collaboration, the company also holds its supplier relationships in high regard. “These are very important because we have a lot of technical products here and we need to have reliable suppliers who are able to provide us with good quality components,” notes Matthias. “They also do a lot of development work with us as we all move forward. Therefore we stick to certain suppliers who are flexible in supplying us according to our own changing demands. These relationships become particularly crucial during difficult times.”

With potential for friedola TECH materials ever increasing with developing trends throughout the industry, the future for the company looks positive. Despite pressures coming from a fiercely competitive market and increasing price pressures, Matthias is confident that the company’s approach to innovation and high quality will put it in good stead to secure further success. In a concluding point he highlights: “The future is going to be very much focused on pushing and developing our CON-Pearl product with new features and applications. We are also looking at consolidating and expanding our packaging systems and LCV products in both our European and US markets.”

SML Maschinengesellschaft

Covering all

areas

Specialising in high performance extrusion equipment for the packing industry, SML is leading the market with unprecedented levels of innovation and technical development

SML Maschinengesellschaft Products: Manufactures extrusion equipment for packaging applications Sites: Four, worldwide www.sml.at

W

hilst the SML name may only be celebrating its twentieth anniversary this year, the company’s expertise spans back almost half a century. SML emerged from the internal works of Austrian viscose fibre producer, Lenzing AG, as a plastics machinery division initially intended solely for the company’s in-house packaging needs. However, with raising demand coming from the outside markets for their equipment, it became apparent the company had stumbled upon a new market and subsequently sold the division on to maintain focus on its own operations. “Twenty years ago, when SML became an independent company, it had already grown to 110 staff generating over 30 million euros,” explains Managing Director, Karl Stöger. “Over that time we have seen growth of two and a half times to 270 people turning over about 80 million euros,

following growth on average of about five per cent a year.”

Serving a range of markets from food and pharmaceutical to general consumer and industrial, SML’s ability to deliver high quality, cutting edge extrusion plastic film and sheet making machines has seen it rise to a leading position in many of its target industries. “We are very innovation led, with our technology often beating everything else in the market in terms of output, productivity, energy efficiency, and film and winding quality,” highlights Karl. “Because of the competitive nature of these markets we have to be trend setters in bring new products to market and driving innovation through the industry. In this respect we have been the first to launch particular solutions many times over our history.”

This is all made possible by a technically superior R&D department, which SML nurtures with

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SYNCRO

SYNCRO is proud to consider itself as a ‘gold partner’ of SML supplying conveying and dosing systems of raw materials.

Thanks to the gravimetric EasyBatch and transport systems sYlink, SYNCRO could meet the high performance of the SML Cast line.

It also provides innovative optical measurement systems OPTYSCAN series installed exclusively on MINICAST line.

Thanks to the compact size and the presence of only one reading head, ‘backscattered’ with Optyscan can be installed directly on the chill roll making the SML line even more compact.

leading engineers and technical experts from a broad scope of disciplines and backgrounds.

“Being based in Austria it is not cost effective for us to operate a lean, high-volume manufacturing process,” outlines Karl. “Therefore, we can only survive by having better technology and a focus on continuous improvement. However, with our strong technical departments we have the capacity to listen to new ideas and demands from the market and quickly turn them into reality.”

To demonstrate this market leading ability to develop cutting-edge innovations for its customer base, SML recently held an in-house exhibition to showcase every range of products in its portfolio. Karl points out that at this year’s event the company had two main highlights on opposite ends of its product scale to demonstrate its diverse range of offerings and technical capabilities. “On one hand we had our smallest, entry-level stretch film machine, the MiniCast which is important for providing smaller companies in developing economies around the world with SML quality,” he says. “And on the other hand we had the MasterCast machine, the biggest, most powerful and most innovative machine on the market, capable of producing in a reliable process stretch film at a web width of six metres wide.” Before this innovation the largest available stretch film lines had reached a possible limit of four to five metres, and it was widely considered that anything beyond this size was impossible.

“Everybody thought we were crazy,” continues Karl. “However we have had it running through a number of tests, even down-gauging the production to 12 microns on a high output test and we have seen it performing extremely well.

We have already shipped a machine out to a customer in Poland and feedback from them and visitors to the show has been very positive. This has been achieved by the technical expertise in our R&D division and is testament to their worldclass capabilities.”

Aside from major, arguably industry changing, innovations such as the MasterCast, SML has a constant focus on making small innovations across its product range. This is done in pursuit of improved stability, film quality, sustainability and energy efficiency – all of which are vital to

SML Maschinengesellschaft SML’s stretch film line ‘MasterCast’ is the world’s biggest

its customer’s remaining competitive in their respective industries.

In terms of market strategy, SML employs a smart approach to ensuring it can remain competitive throughout difficult economic periods.

“We have to be a global company because individual markets can be unpredictable and fluctuate,” expresses Karl. “For instance Asia is currently showing signs of a downturn, but a strengthening market in the US is offsetting this at present.” SML is able to achieve this with sales offices in Europe, the US, Asia and Russia, as well as a number of agents in all key markets across the world. It employs a similar strategy in its product range, ensuring it has a diverse offering that can balance out any demand fluctuations.

Looking ahead, SML is set to continue its

steady growth in order to keep up with growing operational costs. To cope with increases in demand it will be building an additional plant to expand capacity. “We will continue growing by bringing new products to market as well as improving existing ones,” concludes Karl. “Through a process of continuous innovation improving our products in ways that make them most cost effective and energy efficient for our customers, we cultivate a need in the market to continue investment in order to maintain competitiveness.

We then of course have to support this with a high degree of customer service, so continuing to improve customer satisfaction with our service structure will also be key as we look to the future.

If we can help our customers grow, and they are happy with us, then we will grow too.”

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