Bay Engineering future-proofs with Haas

Bay Engineering is a precision engineering company based in Weymouth, Dorset on the Lynch Lane Industrial Estate. The company is committed to providing high-quality CNC machined components while providing prompt and efficient customer service. Established in 2001 by directors Steve Balem and Darren Taylor, Bay Engineering has been going from strength-to-strength.

In 2012, the company moved into a new purpose built 6000 sq ft factory and invested in new machining centres with a prospect to increase its workforce of 13.
“We have expanded our team to 20,” states Taylor. “Our highly skilled staff are augmented by external specialists in their respective fields. This has enabled us to continue our steady growth while making improvements across the company. Ultimately, this lets us deliver an ever-improving service and quality of work to our customers.”
But it doesn’t stop there.
“In 2010, we turned over £320,000. Since then we have steadily grown and have every confidence in reaching our forecast of £1.7m for 2017.”
Adds Balem: “Our culture of continuous investment should see us soon surpass the £2m mark. This will undoubtedly include the procurement of more Haas five-axis CNC mills. We have a long-standing tradition of using Haas. We find them to consistently deliver solid, long-lasting machines, which are great value for money and output quality components.

“Our commitment to quality has always been at the forefront of our current and future plans,” he continues. “We have just received our certification of the latest ISO standard, ISO 9001:2015. We are duty bound to ensure all components we manufacture are fully traceable. From the material purchased, to programmer, to operator, to inspection, through to goods-out.”
More five-axis machining has been an essential part of Bay Engineering’s long-term investment plan for increasing both capacity and machining capabilities.
“We were looking for a five-axis machine to expand our capabilities and had a list of specific requirements,” says Taylor. “Our search for a ‘perfect-fit’ machine began and ended with a call to Haas. They suggested the 12,000 rpm version of the Haas UMC-750 universal machining centre.”

Investing in a CNC machine tool should not require nerves of steel. But, for owners of SME machine shops with a need for high-productivity five-axis machining that is exactly what used to be the case. High purchase cost and complexity were usually enough to put-off those with anything less than cast-iron composure. Until, that is, Haas released its UMC-750 in 2015.
The UMC-750 is designed for both 3+2 and simultaneous five-axis machining. Travels of 762 x 508 x 508 mm and an integrated dual-axis trunnion table are featured. An inline direct-drive, low-heat 40-taper spindle (8100 rpm standard, or optional 12,000 or 15,000 rpm) is offered, while the machine comes as standard with a 40+1 tool side-mount tool changer. The machine provides +35 and -110° of tilt and 360° of rotation for suitable tool clearance and large part capacity.
According to Haas, the UMC-750 is a high-performance CNC machine tool for a fraction of the usual cost associated with machines of such capability and quality.
A wide selection of high-productivity options is available for the UMC-750, including a belt-type chip conveyor, high-pressure through-spindle coolant systems, high-speed machining control software, the Haas Wireless Intuitive Probing System and expanded program memory.
“With 762 x 508 x 508 mm travels, an integrated dual-axis trunnion table and 40+1 tool changer, we knew we had found the right machine for our needs,” says Taylor. “Since taking delivery in March, it has become the most popular machine in the workshop.”
Such an advanced machine requires a similar step up in CAD software. Fortunately, Bay Engineering’s CAD package of choice was ahead of the game.
“We’ve been using OneCNC for over 10 years now,” says Taylor. “It has always worked seamlessly with our existing Haas machines. We have a CAD station attached to each mill for programming and file transfer. This year we’ve upgraded all our CAD stations to Windows 10 Pro and OneCNC-XR7 3D Expert to fully complement our new five-axis machine. We’ve also added modules to OneCNC that provide us with optimum five-axis control while maintaining our existing workflow.
“We have a strict 5S strategy in place, but we take the spirit beyond the obvious tooling and marking,” he adds. “All our CAD stations are configured with the same software connected to a central server providing access to all files at any time. Our ERP software is bespoke and accessible throughout the building. It provides the latest information from the shop floor as required by those who need it, including production status, resource planning and delivery performance.”
Bay Engineering has also started running a night shift, allowing continuous manufacturing around the clock.
“We were looking for a way to increase utilisation of our growing range of machining centres to meet customer demand,” says Taylor. “Adding 24-hour skeleton staff has allowed us to realise and leverage the full potential of our machines.”
Concludes Balem: “Our long-term investment plan since moving to new premises in 2012 has already paid off. We will continue putting our collective expertise, our machines, and our teamwork into ensuring our customers receive the highest quality components with customer service to match.”
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J&S Suprema grinder fits the bill at Bowmill

At its new Tewkesbury manufacturing plant dedicated to the production of Airbus landing gear kits, Bowmill Engineering has installed a Jones & Shipman Suprema Easy cylindrical grinder as part of its multi-million pound machine tool investment programme that includes eight new machining centres and high levels of automation throughout. The factory in Tewkesbury replicates a similar bespoke facility at Bowmill’s headquarters in Poole.

Nick Epps is the managing director of Bowmill and when it came to specifying the grinding machine, he admits a particular affinity with Jones & Shipman: “I’m a time-served toolmaker by trade and a good deal of my apprenticeship was undertaken using J&S manual machines. Here at Bowmill we operate three J&S machines in Poole, while a sister company – Taymar Precision Grinding – also operates a number of J&S machines.
“The Jones & Shipman Suprema Easy is a multi-purpose machine that is known as an ‘all-rounder’ being equally adept at processing high-volume production grinding work or fulfilling high-precision, small batch quantities and one-off work as encountered in environments such as ours,” he continues.
Bowmill has identified nine critical Class 1 kit components that require grinding tolerance finishes – retaining pins, uplock pins and spacers. Some are chrome-plated – a grinding challenge in itself – but all grinding programmes are stored in the memory of the machine’s Easy graphical software which offers a real advantage with its speed of set-up for dressing and grinding cycles utilising touchscreen technology.
Bowmill’s machine has a 650 mm grinding capacity between centres, although longer 1000 and 1500 mm capacities are available.
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El Marakby trusts again in SMS group

After the successful commissioning of a new melt shop and caster supplied by SMS group in 2012, El Marakby Steel, based in 6th of October City, Egypt has awarded the same technology vendor an order for a new rolling mill capable of producing bar and wire rod. The new mini mill will be designed for the manufacture of straight rebars and wire rod coils, and will enable El Marakby to expand its product portfolio and meet increased domestic demand.

El Marakby’s mill will be designed to produce at a capacity of 400,000 tons per year, taking advantage of a hot connection with the existing caster. Starting with square 130 mm billets, and heated to temperature by a 70 ton per hour modern pusher furnace, the mill will be able to produce rebars from 10 to 32 mm and wire rod coils from 5.5 to 12 mm.
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Experience adds value at XYZ

A recent run of long-service awards at XYZ Machine Tools highlights the value of people to a successful business. Out of the 80 employees at XYZ, 30 of them have a combined service of almost 500 years. “Our philosophy has always been that when a customer commits to buying from XYZ, we commit to supporting that customer,” says Nigel Atherton, managing director. “This support ranges from our applications and training teams, which get customers up and running, through to the free programming helpline for users of our ProtoTrak and Siemens controlled machines, as well as the spares and service back-up that we provide with our nationwide team of engineers.”

Recognising that the pool of skilled machine tool builders was getting smaller, XYZ implemented a training plan two years ago that has seen a number of new recruits join the business, including several apprentices who will eventually take up the mantle of applications, programming support and service engineers over the next 10, 20, 30 years.
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Oil & gas sector eagerly awaits ADIPEC

Described as the world’s most influential meeting point for oil and gas professionals, this year’s edition of ADIPEC (Abu Dhabi International Petroleum Exhibition & Conference) is set to take place on 13-16 November. The show is expected to attract more than 100,000 trade professionals from over 135 countries, and over 2200 exhibiting companies, providing visitors a direct route to the world’s most advanced technologies.

Visitors will be able to explore thousands of products and services from 53 countries and 27 international pavilions. The show will provide an opportunity to network with resource owners from around the world who are looking to partners to help them get the most from their assets through operational excellence, cost effectiveness and profitability. In addition, the 2017 Technical Conference Programme, organised by the Society of Petroleum Engineers (SPE), will provide delegates with a comprehensive learning experience covering 119 sessions with over 900 speakers
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