SOUTHERN MANUFACTURING & ELECTRONICS 2026

WES GAINS COMPLETE CONFIDENCE IN COMPLEX MACHINING WITH VERICUT

For precision subcontract machinist WES Engineering Solutions, confidence is fundamental to every machining operation. Manufacturing complex components for demanding industries that include aerospace, defence, nuclear and oil & gas demands absolute faith in every CNC program before the first chip is cut. By integrating Vericut simulation, verification and analysis software into its programming workflow, the Redruth-based company is verifying all four- and five-axis CNC programs before they reach the machine, safeguarding expensive equipment while enabling productive unattended machining.

WES Engineering Solutions employs around 40 people across three specialist divisions. Alongside its subcontract machining business, the company operates a hard metal engineering division specialising in grinding and EDM, together with British Classic Car Performance Braking, which manufactures high-performance brake calipers for classic vehicles. Everything from Austin, Daimler, Ford, Hillman and Jaguar, to Jensen, Land Rover, MG, Morgan, Sunbeam and Triumph.

Across its business divisions, WES machines materials that extend from plastics and copper to stainless steel, titanium and Inconel, machining complex, high-precision components to tolerances as tight as 10 μm, even lower in the case of hard-metal parts undergoing grinding or EDM.

Supporting these demands is an ongoing investment programme in advanced manufacturing technology. Since 2022, WES has boosted its subcontract offer by installing a trio of palletised Matsuura CNC machining centres. An H.Plus-300 four-axis horizontal model with 15 pallets was the first to arrive, followed by two five-axis vertical models, namely an MX-520 with four pallets in 2024 and an MX-330 with 10 pallets in 2026. The extensive pallet capacity provided by these high-performance machines allows the company to maximise lights-out production while increasing flexibility and throughput.

“We found the first Matsuura machine held tolerances exceptionally well, so when we needed additional five-axis capacity it made sense to invest in Matsuura again,” explains James Humphrey, Production Engineer at WES Engineering Solutions. “The latest MX-330 further increases our unattended machining capability, which is becoming increasingly important as customer demand continues to grow.”

Alongside investment in machine tools came investment in Vericut simulation, verification and analysis software. WES currently has one Vericut licence, supporting its Matsuura machining centres. Using Autodesk Fusion 360 CAM software, programmers generate the machining strategy before transferring the job directly into Vericut via its integrated Fusion interface.

“When a new job arrives, we decide on the tooling, fixturing and most appropriate machine before creating the tool paths in Fusion,” explains Humphrey. “Moving the project into Vericut is incredibly straightforward – just a couple of clicks.”

Using Vericut’s Verification, Multi-Axis and Machine Simulation modules, WES simulates every machining process against digital models of its Matsuura machining centres, checking for collisions, over-travel and other potential issues before releasing programs to production. Vericut’s Auto-Diff module provides an additional layer of confidence by comparing the machined component with the original CAD model, highlighting any remaining stock or potential gouges.

“Vericut gives us complete confidence that the machine isn’t going to do something different to what we’ve programmed,” states Humphrey. “We’ve had occasions where the job looked fine in the CAM graphics, but Vericut highlighted something different. It prompted me to go back into Fusion, make a few changes, repost the code and check it again before sending it to the machine.”

For WES Engineering Solutions, independent verification is invaluable. The company regularly manufactures high-value components using equally expensive cutters and machines. Even a minor programming error can result in broken tooling, scrapped workpieces or even machine damage.

“We’ve all heard the stories of programming mistakes causing expensive collisions,” he notes. “Repairing or replacing a spindle on a five-axis machining centre wouldn’t be cheap. Every programmer, however experienced, worries about making that one tiny mistake. Vericut goes a long way towards mitigating that concern.”

The software also transforms and expedites the proving-out process on the shop floor. Rather than operators cautiously monitoring every program with a finger poised over the feed-hold button, they can approach new jobs with considerably more confidence.

“It saves time. What’s more, operators can confidently get on with other work instead of standing there waiting to see whether something goes wrong.”

This confidence becomes even more valuable when programming changes are made late in the working day before machines continue running unattended overnight.

“Confidence is everything,” reasserts Humphrey. “With Vericut, if I make a programming change at the end of the shift, I know I can ask the team to run it overnight without worrying about collisions.”

Before selecting Vericut, WES evaluated several alternatives. Alongside the software’s proven capability, access to UK-based technical support proved an important consideration. Following a trial period that included deliberately introducing programming errors, the decision quickly became clear.

“We wanted reassurance that the software would correctly identify problems before they reach the machine,” he remarks. “During the trial, Vericut detected everything we expected it to. Since then, the ongoing support has been very responsive whenever we’ve needed assistance.”

Although the financial return is difficult to quantify precisely, Humphrey believes the investment continues to deliver value every day by preventing problems before they occur: “The nature of Vericut means you never really know what it’s saved because the incidents simply don’t happen. It could be a broken cutter, a scrapped component or avoiding serious machine damage. In my opinion, more important is the complete peace of mind it provides, allowing us to concentrate on producing high-quality parts and meeting the delivery expectations of customers.”

Quality is everything at WES, which is why software like Vericut is so important to its operations. The company is committed to continuous improvement, investment in systems and automation, long-term capability development, and supporting customers in regulated and safety-critical industries.

WES Engineering Solutions carries accreditations for ISO9001 and the AS9100 quality management system standard for the aerospace industry. In addition, the company holds Fit For Nuclear (F4N), a nationally recognised programme that assesses a company’s capability to operate within the UK nuclear supply chain, and JOSCAR registration, the collaborative accreditation system used by major aerospace, defence and security organisations. WES also complies with Cyber Essentials Plus, a government-backed certification that verifies the effectiveness of cybersecurity controls through independent technical testing.

As WES Engineering Solutions continues expanding into increasingly complex, higher-value manufacturing sectors, confidence remains central to its future growth. With its investment in advanced machine tools and automated production, Vericut provides the assurance that every program has been thoroughly simulated and verified before manufacturing begins. The result? Safe, efficient and reliable machining for the benefit of both WES and its customers.

More information www.vericut.com/en-gb

TALKING DATA: HOW MITSUBISHI ELECTRIC AUTOMOTIVE CZECH TRANSITIONED TO DATA-DRIVE DECISION MAKING

In modern production environments, competitive advantage is increasingly determined by how effectively a manufacturer can capture, connect and act on data. At Mitsubishi Electric Automotive Czech (MEAC), located in Slaný, data has become a strategic asset.

The facility, which supplies electrical automotive components including integrated starter generators to manufacturers across Europe, first opened in 2001. It now employs over 500 people and has evolved from a traditional production environment into a highly connected factory where millions of data points are transformed into real-time operational insight, as it looks to support the automotive industry’s transition towards electrification and smart manufacturing.

Crucially, rather than pursuing digitalisation through wholesale equipment replacement, MEAC has adopted a pragmatic approach that combines proven production assets with connected automation technologies, facilitated by its long-term automation equipment supplier, Mitsubishi Electric Factory Automation. The result is a factory that has made significant improvements to its output, quality, uptime, environmental impact and employee wellbeing.

One of the most striking aspects of MEAC’s digital transformation is its approach to existing infrastructure. While many manufacturers would have pursued a strategy of replacing existing machinery and control systems, for MEAC, the focus has been on extracting greater value from equipment that continues to perform.

“On the production side, we keep what works,” explains Jan Kabát, manufacturing engineering manager. “Our Q-Series control units have been operating reliably for more than 10 years, while modernisation is achieved through a data layer using MES interfaces to connect machines and generate operational insights without disrupting output.”

He continues: “We do not modernise machines simply for the sake of it. The stable Q-Series control remains in place, while connectivity and data capabilities are added where they deliver measurable gains: less downtime, better visibility and faster troubleshooting.”

Such an approach has enabled MEAC to connect more than 100 machines through Mitsubishi Electric’s e-F@ctory architecture. This has created a digital layer that provides visibility into plant performance without incurring significant CapEx costs.

The data generated now forms the basis of day-to-day decision making throughout the factory. It enables engineers to create custom reports and deploy additional sensors where greater process visibility is required.

However, for MEAC, the real value of connectivity lies in the ability to continuously improve manufacturing performance. Digital tools and analytics provide detailed visibility into processes, allowing teams to quickly identify issues and implement corrective actions before they affect production quality or customer deliveries.

For Dalimil Bartoň, general manager, data has become central to the company’s continuous improvement strategy: “We use data to drive continuous improvement in both process and product quality. By analysing detailed manufacturing data, we can identify defect patterns, optimize processes and reduce scrap. The result is more consistent quality for customers and lower manufacturing costs for the business.

“The point isn’t about using technology for technology’s sake. It’s knowing how to deploy systems so they genuinely support production within a true PDCA cycle. By using Mitsubishi Electric FA’s portfolio in a pragmatic way, the team continues to raise automation levels, protect quality, and deliver measurable results on the shop floor.”

While digital transformation is often associated with plant equipment, MEAC has also applied data-driven techniques to improve working conditions for employees. The company uses RFID technology and workstation data to understand how work is performed across the facility and identify opportunities to reduce physical strain.

Petr Soukup, manufacturing senior manager, explains: “We use RFID technology to identify operators and understand where they are working, combining this information with muscle-load and workstation-level data. This helps us plan job rotations and organize work more effectively to reduce ergonomic strain. As a result, we’ve achieved more consistent performance across shifts.”

With MEAC also understanding the impact of environmental conditions on production performance, the facility represents a comprehensive software-defined building based on Mitsubishi Electric iQ‑R PLCs and ICONICS GENESIS64 software.

According to Milan Koňarik, facility manager, the system provides a single view of critical facility infrastructure. “Our software-defined building is built on ICONICS and GENESIS64, with Mitsubishi Electric iQ-R PLCs. This allows us to actively manage the plant environment and its impact on production.”

He adds: “We monitor HVAC, the data centre, pre-cooling systems, UPS and other technical utilities, with over 3000 measurement points feeding a single data view for faster decision-making. The system can trigger SMS and email alarms, support smarter energy purchasing and help our energy-saving team act quickly. We see it as a practical tool for reducing energy costs and operational risk while keeping our carbon neutrality ambitions on track.”

Ultimately, as automotive manufacturers continue to face pressure to improve efficiency, quality and sustainability, MEAC shows how effective digital transformation can be achieved without disrupting established production processes.

With improved visibility of key data points, reduced downtime, enhanced product quality, lower energy consumption and a more sustainable working environment, MEAC has truly managed to get its data talking.

More information https://emea-fa.mitsubishielectric.com/fa/

A CHANGE OF MACHINE STYLE BRINGS BENEFITS TO COMBINED ENGINEERING SERVICES WITH INVESTMENT IN XYZ TMC

Combined Engineering Services (CES) was born following the 2018 merger of Brecon Designs (formed in 2007) with another local engineering company, Infinite Engineering Design. Since then, managing director Steve Willams and his team have seen continued growth.

From humble beginnings with a facility housing little more than a turret mill, manual lathe and wire eroder, CES now has substantial CNC machining capability. This allows the company to manufacture tooling, jigs and fixtures, along with the design and build of special-purpose machines. The aim of CES is to build lasting customer relationships by working with integrity to provide cost effective solutions, providing mutual security for both parties.

CES made its first step into CNC milling by investing in an XYZ VM 4000 bed mill, with Willams outlining that it was the ProtoTRAK control that made the company gravitate towards XYZ.

“As with many companies, our first step into CNC was made with great trepidation but we gelled with ProtoTRAK control,” he confirms. “Since that first machine, we now have seven more XYZ bed mills with different capacities and generations of controls, along with a flat-bed lathe that also has the ProtoTRAK CNC.”

This progressive and forward-thinking business located just off the ‘Heads of the Valleys’ in South Wales has now made further investment to enhance its capability and help to improve productivity.

Chris Bow, design director at CES, explains: “The bed mills have served us well and continue to do so, but it became apparent that we needed to try something different on our next machine tool purchase to remain competitive. When we’re not successful in winning work following a quote, we always look at why didn’t we win the job. These investigations led us to look at our machining capability.”

He continues: “We arranged a visit to the XYZ head office in Devon to look at several options. On our return we concluded – following the advice provided by the XYZ sales team – that the 750 TMC with its enclosed layout would be a good fit for our business.

“We knew the TMC would allow us to improve material removal rates and reduce cycle times due to its 11 kW BT40 spindle. In addition, the travels of 743 mm in the X axis and 425 mm in Y, mated with the 20 station BT40 tool changing carousel, would open up the opportunity to load a number of parts on the bed at the same time. In turn, this would push us towards lights-out machining and subsequently help us achieve the goal of lowering our manufacturing cost per part.”

Chris continues with the justification of the purchase by adding: “Another improvement for the business was better staff utilisation due to less operator input during component manufacture. The potential to walk away from the machine for the whole of the process brings its own increase in efficiency, creating more capacity within the workshop and helping to reduce takt time when we build one of our special-purpose machines”.

Now the new machining centre is up running, CES is benefitting from the flexibility that the XYZ TMC range offers. Having taken advantage of the optional front-mounted electronic handwheels, all the programmers and operators at CES can jump on the machine and use it in a manual capacity for simple machining operations if required.

The transition to the XYZ TMC from existing bed mills at CES was easy due to the resident conversational programming in the control. Having made an investment in CADCAM software, CES is now in a position to use all of today’s latest technology, both on the ProtoTRAK 15” touchscreen RMX control or through CADCAM to manufacture parts quickly and cost effectively.

XYZ’s TMC (Toolroom Machining Centre) brings the added versatility of a tool-change system, while maintaining the familiarity of the latest version of the ProtoTRAK control system. The use of the RMX ProtoTRAK CNC provides a high level of familiarity for exiting users of XYZ bed mills. For those not familiar, its touchscreen interface and easy-to-use programming tools make the control suitable for low-to-medium production batch sizes. Combining that with a fully enclosed machining envelope and either a 12- or 20-station automatic tool changer, make the XYZ TMC a great choice machine for any business looking to step up productivity.

“The one thing that we didn’t see coming when the machine was installed was the enthusiasm from the team of machinists here at CES,” reports Chris. “They all have a desire to use the machine and help the business reap the benefits of this new technology. Due to software enhancements – such as the ‘defaults’ setting where operators can set the control features to their own liking, the TRAKing feature to put them in control by winding handwheels to execute the program, and the fact the machine has been fitted with a swarf conveyor to cut down on machine cleaning time – all the team have shown willingness to get involved.

“This is helping the company move forward and be more competitive when it comes to quoting for work as the enthusiasm from the team means they’re now looking at manufacturing parts in a different way and employing production methods that were not possible on our older machines. It’s not just the machine that’s making a difference here at CES but the staff too.”

Today, the workshop team at CES is able to offer a complete range of services from CNC milling and turning, through EDM to metal finishing and machine building. The company’s acquisition of the adjoining unit in 2021 allowed it to expand into clearly defined work areas, giving a more controlled production flow from workshop through build and inspection.

More information www.xyzmachinetools.com

BEMA INVESTS IN HIGH-QUALITY MANUAL MACHINES FROM MACH MACHINE TOOLS

For more than a decade, BEMA (British Engineering Manufacturers’ Association) has been investing in manual machine tools from MACH Machine Tools to ensure its engineering apprentices develop the practical machining skills that employers across the southwest of England continue to demand.

The latest investments form part of an ongoing commitment by BEMA to provide apprentices with relevant, transferable workshop experience before they return to their employers to complete the remainder of their training. To date, the organisation has purchased 11 manual machines from the Bristol-based supplier, including six MACH L-1340 centre lathes and five MACH VS-1 vertical milling machines.

The machines are installed at BEMA’s dedicated engineering training centre in Yate, South Gloucestershire. Operated in partnership with Swatpro Academy, the purpose-built facility delivers practical training for Level 2 and Level 3 engineering apprentices in machining, fitting and maintenance. The centre serves employers across the region, helping develop the skilled workforce required by the area’s diverse manufacturing and engineering industries.

Engineering apprenticeships supported by BEMA and delivered through Swatpro typically span four years. During the first year, apprentices spend ten months at the training centre, attending full-time from September through to July before returning to their respective employers to complete the remaining three years of their apprenticeship.

Following an initial induction period, apprentices undertake a structured programme divided into six-week training blocks. Each block comprises two weeks of turning, two weeks of milling and two weeks of fitting, providing a balanced introduction to the core engineering disciplines while allowing instructors to monitor progress through regular assessments and practical inspections.

“Our turning, milling and fitting modules are very much practical, skills-based programmes,” explains Andrew Dunster, lead workshop and commercial training instructor and assessor.

“By the time apprentices complete their first year, they have developed a solid level of technical competence across all three disciplines. Those skills provide the foundation they need when they return to their employers, where they continue developing throughout the remainder of their apprenticeship.”

Throughout their training, apprentices use the MACH lathes and milling machines to manufacture a wide variety of precision components from materials including mild steel, alloy steel, aluminium, brass and engineering plastics.

Rather than producing simple practice pieces, the machining projects are deliberately designed around functional workshop equipment that apprentices can use during subsequent training. These include thread vices, go/no-go gauges, location plates, V-blocks, toolmakers’ clamps and precision vices.

“Our apprentices are machining practical tools that have a genuine purpose, rather than simply producing parts with abstract features,” says Dunster. “It gives greater meaning to the work while reinforcing the importance of accuracy and good machining practice.”

Producing these components requires considerably more than simply operating a machine tool. Apprentices must learn to read and interpret engineering drawings, select appropriate tooling, safely set up each machine and consistently achieve the specified dimensional tolerances and surface finishes.

On the lathes, this includes operations such as external and internal turning, facing, parting-off, grooving, drilling and thread cutting. Milling exercises include face milling, end milling, drilling and boring, helping apprentices build a broad understanding of conventional machining processes before progressing to more advanced manufacturing technologies.

According to Dunster, the reliability and usability of the MACH machines make them particularly well suited to an educational environment.

“The MACH lathes and milling machines are accurate, reliable and straightforward to use,” he says. “That consistency is important when you’re teaching apprentices because it allows them to concentrate on developing sound machining techniques and good workshop practices.”

Value for money has also been an important factor in BEMA’s purchasing decisions.

“The machines are competitively priced and supplied with a comprehensive range of standard equipment, including tooling packages, chucks, steadies and digital readouts, rather than these being optional extras,” he adds. “That makes them an attractive proposition whenever we evaluate new equipment.”

This combination of technical capability, competitive pricing and educational support proved decisive when BEMA invited tenders in 2019 for a further six manual machine tools comprising three MACH L-1340 lathes and three MACH VS-1 milling machines.

For Martin Wear, BEMA’s centre manager, the decision extended beyond the machines themselves.

“MACH Machine Tools presented a strong technical proposal, but what also impressed us was the company’s understanding of the education and training sector,” he explains. “Its experience of working with training providers, together with the additional support and sponsorship it offers educational organisations, helped distinguish its submission.”

Today, the MACH machines play a central role in the day-to-day operation of the training centre.

The MACH VS-1 manual milling machines feature rigid construction, generous table capacities, variable-speed 5,000rpm spindles and two-axis digital readouts, while the MACH L-1340 centre lathes combine compact footprints with features including quick-change tool posts, precision tailstocks, stress-relieved beds and two-axis digital readouts. Together they provide apprentices with the robust, accurate and dependable platform needed to develop fundamental machining skills.

As engineering employers continue to seek apprentices with strong practical capabilities alongside theoretical knowledge, BEMA believes that investment in high-quality workshop equipment remains essential.

“We currently have 11 MACH machine tools in our training centre,” concludes Wear. “They continue to perform reliably year after year and play an important role in helping us develop the turning and milling skills our apprentices need before they progress into industry. Ultimately, that’s what this investment is all about: giving employers apprentices who are confident, capable and ready to contribute from day one.”

More information www.machinetoolsalesonline.com

Programming made simple

Hurco (Stand G200)is demonstrating the latest software developments on its Max5 control. They include a solid model import option, which enables the creation of conversational programs directly from an STP file. Similarly, 3D DXF files may be imported and worked on seamlessly.The 19-inch colour touchscreen control supports the easyprogramming ofa first-off part, withsimple conversational prompts guiding the user through program stages, taking the load off CAM stations. Offline-generated NC code can be added into the program using an NC Merge function. Live on-line help is available at the control.More information www.hurco.com