Cutting edge for Whiteley & Sons

A Sheffield-based scissor manufacturer that supplies royalty, Formula One teams, golf courses and bulletproof jacket specialists has invested in three new machines to help it meet an unprecedented rise in sales.

William Whiteley & Sons, which has been trading for more than 260 years, has spent in excess of £80,000 in upgrading its production capability to include state-of-the-art vibratory finishing technology.

Boosted by a capital grant from the Manufacturing Growth Programme (MGP), the latest addition brings automation to the company for the first time, helping it redeploy crucial labour to more value-added work and provide a 30% increase in capacity.

“When it comes to producing scissors and shears, we have some of the best craftsmen and women in the world,” explains company director Jeremy Ward. “We needed to protect those skills by investing in new technology that would automate a labour-intensive, low-skilled process, and that’s why we pressed the button on the capital spend.

“The vibratory finishing machine provides repeatable quality and the option to manufacture through the night,” he continues. “It also gives us the smoothest and most aesthetically pleasing finish possible, which is what customers for our scissors and shears demand. Sales in this arena now account for 30% of turnover and our beautifully crafted products are being used by tailors on Saville Row, by major fashion labels and by the army of people who are turning to crafts during COVID-19.”

William Whiteley & Sons, which employs 15 people and boasts a £1.1m turnover, has been working with the Manufacturing Growth Programme to identify and overcome production bottlenecks.

For further information www.manufacturinggrowthprogramme.co.uk

Total Carbide opts for Micromatic

Master Abrasives has installed a Micromatic Pluto 18 grinding machine at Aylesbury-based Total Carbide, a manufacturer of sintered tungsten-carbide wear parts.

Total Carbide was looking for a cost-effective new machine for its tungsten-carbide measuring probes. The component has a chamfer on the front corner which was ground by interpolation on the company’s previous machine.

Required stock removal on the measuring probe is 0.5 mm on diameter, while surface finish is 0.4 Ra with an outer diameter and length tolerance of ±0.25 mm. The new machine had to accommodate a volume of 2000-3000 pieces per month and it was necessary to have a Fanuc CNC to grind OD, face, chamfer and corner radius features, allowing a smooth transition for operators.

Micromatic’s Pluto-18 is best suited to the production of accurate, small components, and can perform both plunge and traverse grinding operations. Several features of the machine identify its suitability for the batch production of shaft-type components with a maximum wheel outer diameter of 400 mm (50 mm width). For instance, a rigid anti-friction wheel head is utilised for better geometrical accuracies, while an integrated table provides higher rigidity.

The Pluto-18 measures only 1.66 x 2.2 m, which can help to save nearly 30% in space compared with the footprint of a similar hydraulic grinder. Furthermore, the machine’s customised user-friendly graphics aid machine setting and operation.

Master Abrasives can show Micromatic machines in action at its grinding and finishing showroom in the Midlands, along with superfinishing devices, metrology equipment and abrasives.

For further information
www.master-abrasives.co.uk

Quick on the uptake

Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, has supplied Quick Machining Solutions, a precision subcontract specialist based on the outskirts of the New Forest, with a new vertical machining centre. The machine, a Doosan DNM 4500 three-axis machining centre, was installed at Quick Machining Solutions’ refurbished 7000 sq ft facility in September 2020.

Investing in a new machine tool during the pandemic, at a time when many manufacturers were “battening down the hatches” has helped Quick Machining Solutions meet growing demand for its machining capacity and capabilities.

Explains Wayne Harris, owner and managing director: “A number of component manufacturers closed down their operations and/or furloughed a significant number of staff in response to the pandemic. We felt that even in these uncertain times, we had an obligation to remain open while ensuring we did everything to keep our staff safe. We also used any spare time for training, maintenance and other improvements within the business.

“As a consequence of keeping our doors open we were able to pick up new work from a number of customers who were having difficulty sourcing their machined parts in the necessary timescale,” he continues. “This increase in demand, in addition to continually improving our machining capabilities, was the main catalyst behind the DNM 4500 investment.”

To ensure that the new machining centre would meet its immediate and future production requirements, the company drew up a checklist and investigated the market.

“We needed a high-performance three-axis machine with a compact footprint and a good-sized working envelope to handle a wide range of different-sized parts,” says Harris. “Also, we required a machine with a Heidenhain 640 control to integrate with our existing database of machines and programs.”

He adds: “We’d looked at purchasing a Doosan DNM 4500 at the start of the year but had postponed the decision, temporarily as it transpired. However, the increase in demand and the need for swift delivery, combined with a great purchase price, meant that the investment was given the go-ahead.”

Since being installed, the DNM 4500 has been used to machine a range of components for customers operating in the motorsport, film, leisure and industrial sensor sectors, to name but a few. These parts, machined in small-to-medium batch sizes and from materials that include aluminium, stainless steels, titanium and engineering plastics, often exhibit tight tolerances (down to a few microns in some instances) and surface finishes of Ra 0.1 µm.

The DNM 4500 machine supplied to Quick Machining Solutions is equipped with a direct-drive 12,000 rpm spindle, a 1000 x 450 mm work table, a 30-position ATC and a Heidenhain TNC 640 control. Further features include roller LM guideways and thermal error compensation to ensure high accuracies and repeatability over long machining runs.

Says Harris: “The DNM 4500 is versatile and a great all-round performer. We ordered the machine in September and in the same month it was delivered, installed and cutting metal.”

Founded in 2010, Quick Machining Solutions has achieved significant growth and success over the past 10 years. The company today employs eight members of staff, has substantially increased its turnover and, to win new business and secure its position within customer supply chains, has achieved ISO9001 accreditation. Its commitment to continuous improvement is further reflected in strategic and prudent investment in machine tools and ancillary technologies, as evidenced by its first Doosan machine acquisition around two years ago.

In November 2018 Quick Machining Solutions invested in a Doosan Lynx 2100LMA multi-axis turning centre with an integrated servo-driven bar feeder.

“To maintain our competitive edge we made the strategic decision to invest in a flexible, high-performance multi-tasking turning centre,” says Harris. “We were looking for a lathe that was fast, powerful and accurate, and we were specifically keen on acquiring a machine that was equipped with driven tooling to help us reduce set-up and part cycle times. A bar feeder was also required to help us improve productivity and facilitate ‘lights-out’ and unattended operations.”

Before taking any purchase decision, Quick Machining Solutions did its homework and researched the market. The results revealed that Doosan lathes were popular among component manufacturers and that, for small component production, the Lynx range came highly recommended.

On the basis of its findings, which also included visiting an existing Mills customer and Lynx lathe user, Quick Machining Solutions placed its order for a Lynx 2100LMA.

Says Harris: “The Lynx lathe is a real workhorse and, since its installation, hasn’t missed a beat. The performance and reliability of the Lynx lathe, and the ease of doing business with Mills, were major factors in us deciding to invest in the DNM 4500.”

Investing in new technology as well as its people, plant and manufacturing processes and systems, is definitely the “direction of travel” for the company moving forward. Other recent and planned investments to enhance its performance include: the recent purchase/integration of an MRP system to help improve productivity and operational efficiencies; investment in a new CMM to boost inspection capabilities; the roll out of a plan to generate solar energy; and the continuation of the firm’s in-house apprenticeship programme.

“We’re always looking to improve and innovate,” concludes Harris. “We’ve built a solid reputation in the market based on the quality of our machined components, the fast turnaround times we can achieve for customers and our competitive prices. In a relatively short space of time we’ve become a ‘go-to’ precision component manufacturer for customers operating in number of industries. Our investments in Doosan machine-tool technologies have been more than instrumental in helping us get to where we are.”

For further information
www.millscnc.co.uk

Investment incentive extended

To give “a much needed confidence boost to the marketplace”, Ward Hi Tech has extended its incentivised purchasing scheme to October 2021. The move means that customers can secure a new machine tool today and have it distributed within a fortnight to any premises in the UK or Republic of Ireland, but not start paying for it until October.

Ward Hi-Tech is anticipating an impending uptick in business, stating: “With three vaccines about to be rolled out in the next few weeks, a ray of light is now clearly visible at the end of the COVID-19 tunnel.” Alongside the long-term payment holiday and attractive cash-flow scenario, together with a significant saving in interest costs and potential reduction in year-end tax bill, the company describes the benefits of the scheme as “endless”.

For further information www.wardhitech.co.uk

Transmission of quality at Ricardo

A recently installed Studer S33 CNC universal cylindrical grinding machine is helping operators at Ricardo Driveline and Transmission Systems to maintain their high-precision grinding standards.
The Leamington Spa facility operates four Studer CNC universal cylindrical grinders, including a recently installed S33 model. Since its installation, the Studer S33 has been busy undertaking the grinding of development and prototype components, as well as small production runs.

Production team lead Victor Smith says: “When compared with the other grinding machines that we considered, the Studer S33 proved to be the ideal solution for our demanding needs. Also, considering its impressive specification, we were surprised that it was only marginally more expensive than its less capable competitors. Further factors that influenced our decision were the consistent high-quality of the components that we grind on our existing three Studer machines. Also, over many years we have enjoyed excellent aftersales support from Studer and the company’s UK agent Micronz.”

The components produced by Ricardo have demanding technical specifications related to parameters such as surface finish, roundness and dimensional tolerances, and the Studer S33 is helping the company to adhere to all of these requirements.

Studer supplies the S33 with optional distance between centres of 400, 650, 1000 or 1600 mm, and a centre height of 175 mm. The maximum workpiece weight is 150 kg.

An automatic swivel with 1° Hirth serration positions the wheel head. The machine also has an external wheel head with a grinding wheel on the right with degree separations of 0°/15°/30°. An optional C axis is located on the S33 work head for thread grinding, while the workpiece table features a double T-slot to accommodate dressing devices.

For further information
www.micronz.co.uk