SUBCONTRACTING NEWS

Bharat Forge Daun relies on Emag machines

Unusually sophisticated components and high-strength materials for high-tech applications, like stator housings for electromobility with tolerances in micron range, are among the machining challenges tackled by the specialists at Bharat Forge Daun in Germany. At the centre of this activity areseveral vertical turning lathes (VTLs) from Emag, which operate around the clock, five days a week.

The vertical design of thesemachines played an important role in the investment decision, asa horizontal machine from another manufacturer had caused difficulties in the past. Annoying chip clusters would form, requiring manual removal two or three times a shift.

“It was therefore obvious to us that we should carry out these processes in machines with a vertical design, because their unhindered chip flow prevents disruptions,” explainsChristoph Steffens, head of mechanical engineering at Bharat Forge Daun. “Our objective was to achieve maximum process reliability.”

Another factor in the decision in favour of Emag was existing knowledge: the machine tool manufacturer used examples from other customers toshow how its machines optimise stator machining – with low non-productive times and high-precision handling processes. Integrated automation, including a pick-up spindle and lateral conveyor belt, ensures fast processes, while the stable base body is made of Mineralit polymer concrete.

Last but not least, the response time and the expertise of Emag’s service department play an important role for Bharat Forge Daun. A regional service technician is always on site within a few hours and solves any problems directly.

“So far we have always been helped with minor faults in record time,” says Steffens.

For further information www.emag.com

Leadership transition at Dean Group

Manchester-based casting specialist Dean Group is implementing an important strategic shift as part of its leadership succession plan. Effective 1 July 2024, Pulkit Ahuja will take up the role of managing director, succeeding the retiring Graham Stubbs. Pulkit, a key member of the Dean Group team since 2019, has been selected for his proven proficiency in directing the company’s commercial operations, contributing significantly to its enhanced positioning within the casting industry. This planned succession reflects the company’s commitment to a seamless transition in leadership that ensures continuity.

For further information www.deangroup-int.co.uk

Automatic loading and blasting without ‘teaching’

When Ottostahl GmbH had to replace an old rotary table shot-blast machine, the company insisted on short cycle times, high energy efficiency and relieving its personnel from strenuous and monotonous physical activities. Rösler and automation specialist Teqram met these challenging demands with the universally deployable Easy Shotblaster RDT 150 rotary table, equipped with a stationary ‘intelligent’ robot. This robot places workpieces on the rotary table in a manner that optimally utilises the entire table area without requiring any ‘teaching’ operations.


Ottostahl in Magdeburg produces up to 30 mm thick, highly precise plasma-cut and up to 300 mm thick flame-cut components. In its shot-blasting department the company is
utilising three machines (two continuous flow roller conveyor machines with an operating width of 3800 mm and a rotary table blast machine). After more than 60 years of use, the company is replacing its old rotary table blast machine with an RDT 150 system from Rösler.

The entire blast system integrates within a manufacturing cell measuring 8 x 8 m, consisting of an intelligent stationary robot and the RDT 150 shot-blast machine.

With its image processing technology, the vision-controlled robot automatically recognises components placed into its working section, completely independent from their position on the pallet. This capability eliminates the normally required time-consuming teaching or programming of the robot. Moreover, with the intuitive interface, no special knowledge is necessary.
After the automatic selection of a suitable gripper from the magazine, the robot picks up components and places them on the rotary table in the optimal position. It provides component data to the machine controls for selecting a suitable processing program. Halfway through the cycle, the robot automatically turns the components to blast the other side. The robot then returns finished workpieces to the pallet.

For further information www.rosler.com

Recol to invest in automated fibre welder

Recol Ltd, a provider of sheet metal fabrication, precision machined components and mechanical assemblies, has placed an order for a new Amada FLW ENSISe 6 kW automated fibre laser welding machine. The first model of its type in Europe, the FLW ENSISe will enhance the quality and repeatability of the company’s welding operations while in many instances eliminating a number of on-processes, including straightening, grinding and polishing.

“We currently rely on manual TIG welding, but it’s becoming increasingly difficult to source the skills,” reports Recol’s managing director Ben Guntrip. “We were waiting for the right time to invest in an automated solution: that time is now. Recol likes to be first out the gate as it gives us something in the initial 6-12 months that is unavailable elsewhere, potentially providing a pathway into new customers and markets.”

For further information www.amada.eu

A&M EDM secures over £600,000 in grants

Between 2014 and 2022, Smethwick-based A&M EDM, a supplier of precision engineering services, has revealed that it received grants totalling £607,000 from a variety of providers. This funding helped support activities such as investment in machinery, innovation projects and digital marketing, as well as invaluable tailored support from the region’s accredited business advisers.

“My ambition from the outset was to become a sustainable subcontractor offering EDM manufacturing,” says founder Mark Wingfield. “The reduction of the Midlands toolmaking and automotive industries created opportunities to grow the business in other sectors such as aerospace. The advice I’d give to anyone starting today is to add value to every customer and continuously reinvest in equipment and employee training.”

From humble beginnings in 2002 with two employees and one machine, fast-forward to 2024 and A&M EDM has 84 employees, 80 machines and an annual turnover over £8m. The company is an award-winning business and the current Make UK Midlands and East region SME of the year.

By being open-minded to the support on offer from external organisations such as Business Growth West Midlands, Wingfield ensures the business accesses opportunities which serve the values of the company. Among those values is training the next generation of engineers. A&M EDM currently has five apprentices, and nine other employees who have advanced from apprentice level, including two section managers.


Working with Dudley College, the company has delivered an Advanced Engineering Apprenticeship since 2014, focusing on both the technical aspects of the job and soft skills. Apprentices continue to be an integral part of the team and future planning of the company, with a focus on retaining these skilled workers through their careers.

For further information www.amedm.co.uk