SUBCONTRACTING NEWS

Trusted partnership drives growth at Billington

Think back to when Manchester United secured the treble, The Matrix redefined cinema and the Millenium Dome was London’s latest architectural icon. Around that time, Billington Structures Ltd and Ficep UK began a partnership that has stood the test of time. Over 25 years later, this collaboration – based on shared goals and trust – has helped Billington, a major UK structural steel fabricator, improve its operations and remain at the forefront of its industry.

The introduction of Ficep Gemini machines marked a key step in the partnership. These machines allowed Billington to handle multiple tasks, such as chamfering, drilling and plasma cutting – on a single platform.

Billington also turned to Ficep for its laser processing technology. The company purchased a Ficep Cutlite machine, capable of cutting material up to 50 mm thick. After seeing the machine in action at Ficep’s UK open house and later visiting the factory in Italy, Billington was convinced of its capabilities.

Kevin Campbell, managing director of Billington Structures, says: “The thing that impressed us most was its ability to process material up to 50 mm thick. Since its installation, we’ve found the productivity much better than we expected, while the quality of parts is second to none.”

Ficep provides ongoing support, including maintenance contracts and complementary solutions like its vending machine for consumables.

Says Campbell: “The Billington/Ficep partnership over the past 25-30 years has seen us grow as a business, offer more products, and maintain our competitiveness and productivity. And part of the reason for that is the support we’ve had from Ficep.”

More information www.ficep.co.uk

Laser cutter boosts output at Expanded Metal

When The Expanded Metal Co recognised that its costs for external subcontract laser cutting services were escalating in line with output, the Hartlepool-based manufacturer investigated the market for a fibre laser cutter to help manage costs and enhance process control. The solution arrived in the shape of a Lincoln Electric Linc-Cut 1530A 6 kW fibre laser cutting machine from Kerf Developments.

Recalling the situation, Ryan Pinder, operations manager and head of continuous improvement at ExMesh, says: “Our laser cutting costs were climbing, and production schedules worked on min-max order levels with our supplier. It had to change. We looked at 8 to 10 laser manufacturers and did our due diligence. Part of this included visiting the MACH 2024 exhibition, where we talked to a contact at Lincoln Electric, which was sharing a stand with UK agent Kerf Developments.”

He continues: “This was our first laser purchase, so we needed support and reassurance as we leapt into the unknown. The Kerf team put us at ease and emphasised their level of support, and they couldn’t have been more supportive during demonstrations. We switched our original requirement from a 3 kW to a 6 kW   laser cutter to future-proof our business, and Kerf introduced us to the Lincoln Electric Linc-Cut 1530A.

“While we have to build labour and consumable costs into our ROI projections, we’re already using the machine for much more than originally intended – meaning it will pay for itself in the very near future.”

Concludes Pinder: “With the Linc-Cut 1530A, we’re now in charge of our destiny, and we’re already receiving more bespoke subcontract jobs from existing customers.”

More information www.kerfdevelopments.com

Apprentices wanted

Sheffield Forgemasters is looking to recruit 21 apprentices for 2025 as it builds an employment base for one of the world’s most advanced manufacturing facilities. The recruitment is the first of two tranches in 2025, with more places due to be announced in the coming weeks as the company drives forward a £900m investment to build a new 13,000 tonne forging line and a 30,000 m² state-of-the-art machining facility. Successful applicants will join the Ministry of Defence owned company to participate in an award-winning apprenticeship scheme that builds skills for the future.

More information www.bit.ly/4iMPNTE

Automation investment delivers major benefits

Mills CNC has recently supplied Ayrshire Precision, a precision subcontract specialist, with two new SYNERGi systems.The systems, both derivations and highly-customised versions of Mills’ standard SYNERGi ‘Sprint’ solutions, were installed at Ayrshire Precision’s 1300 m² facility in 2023, the first retrofitted to a DN Solutions Puma 2600SY lathe in March, and the second, also retrofitted, to a Puma 2100SY in September.

SYNERGi Sprint automation systems are compact, flexible and cost-effective.They are suitable for integration with DN Solutions’ lathes, machining centres and turn-mill machines to create automated manufacturing cells.The basic elements of a SYNERGi Sprint system comprise: a FANUC industrial robot;two- or three-jaw pneumatic grippers (end effectors); a part loading/unloading grid plate; industrial safety guarding; and SYNERGi software and a 17” touchscreen HMI for programming and monitoring.

Chris Hepburn, Ayrshire Precision’s managing director, says: “We liked the design and build of the SYNERGi Sprint system:it was simple and straightforward.We asked Mills to put forward their plans and proposals for two SYNERGi Sprint cells – one incorporating our existing Puma 2600SY for larger parts, and the second incorporating our Puma 2100SY for smaller components.

“The investment in our two SYNERGi cells is paying dividends. We have two inherently flexible automated cells that, to a large extent, not only help us future-proof our small turned part operations but also increase our overall capacity.Although initially there was some anxiety concerning our move towards automated production, the results have exceeded expectations. Working in collaboration with Mills has enabled us to benefit from unmanned production and become more productive and profitable as a consequence.”

More information www.millscnc.co.uk

Direct route to success with SMEC turning centre

When Direct Engineering & Site Services Ltd opened its doors in Sheepbridge, it was a small fabrication shop. Fast-forward 28 years and the Chesterfield-based company operates from a 3716 m²premises with five divisions that deliver diverse services to customers throughout the UK and Europe.

Direct Engineering specialises in the installation of material handling equipment, vacuum conveying and chiller pipework systems. Dugard has frequently supported the company via its range of machine tools, with the latest acquisition being a SMEC SL 3000LM turning centre.

Ray Woolley, managing director of Direct Engineering, says: “We started in 1997 as a fabrication company that initially machined on a smaller scale. As time progressed, we saw the need to expand our operations as our customers requested more machining services, so we invested in CNC machines.”

He continues: “We’re presently undertaking quite a diverse range of work for industries from marine, automotive and pharmaceutical to power and the water utilities. We machine everything from plastic, brass, and aluminium to stainless, duplex, composites and more.”

To accommodate this variety of materials, the versatility of the Dugard SMEC SL3000LM machine is paying dividends.

“Each material has its challenges regarding how it cuts, but Dugard helped us with a machine breakdown and quickly got us up and running,” says Woolley.“For that reason, we continued our relationship with Dugard. We’ve had a lot of good productive advice from Dugard on how to deal with this diverse range of materials.”

The latest SMEC SL 3000LM is not the first Dugard at the Derbyshire company. Direct Engineering has a range of machines from Dugard, including the SMEC PL2500, PL35 and PL45 turning centres.

“Dugard has provided sound advice on the best machine tool options for our needs,” concludes Woolley.

More information www.dugard.com