UK NEWS

Fivefold increase in machine productivity

Having over 50 years of experience in engineering, Team Inc (UK) is a company that specialises in leak-sealing services and solutions. With offices in Carlisle and throughout the UK, Team Inc has grown into a global brand with a reputation that extends from here to its headquarters in the US.

Among the company’s best-selling components are high-pressure injection adapters, which are finish-machined using reamers against a 24/7 schedule. The reamers used previously to machine these high-pressure injection adapters, made from high-tensile alloy steel (A193B7 and A320-L7), allowed Team UK’s engineers to produce between 1500-2000 parts a year. However, reamer wear was prone to causing component damage, leading to scrapped materials and waste. Ceratizit therefore recommended its Fullmax reamer.

Cutting data for the new reaming process was 1722 rpm with a feed rateof 1722 mm/min (1 mm per revolution feed). Saving 50 seconds per component, Team UK managed to increase its throughput to between 8000 and 10,000, equating to a fivefold increase in productivity.

Ceratizit’s new Fullmax Reamer also meant that fewer components saw damage during the process. As another benefit, whereas the new Fullmax Reamers show when they need replacing, there was no way for engineers to tell if the old reamers were wearing.

Chris Mitchell, manufacturing manager at Team UK, says:“Normally, when you want to increase process efficiency as much as this, there is a huge expense either through providing more manpower or buying expensive equipment. However, the new reamer was actually cheaper than the one we were using previously and it has provided a fivefold increase in the production of this adapter, which is absolutely outstanding. As well as this, it has virtually eradicated any waste in terms of scrapping parts.”
For further information www.ceratizit.com

Space Week set for lift-off in Cumbria

Later this month, manufacturers in Cumbria will have opportunities to see how they can diversify into the space industry. ISH (Industrial Solutions Hub) is hosting Space Week across West Cumbria on 26-30 June. The event will feature a wide range of speakers from the space industry, who will address business delegates at Lakes College, Workington on 26-28 June. Leaders from the UK Space Agency, the Satellite Applications Catapult and businesses already operating in the space sector will share information on how the market works. The Space Skills Alliance will also deliver a workshop presenting the skills needs of the industry.
For further information www.bit.ly/3IKHIPF

Manufacturing analytics software supports 30% growth

A precision machining company has achieved 30% growth in turnover following the installation of a manufacturing analytics platform. Chesterfield-based Sterling Machining installed FourJaw’s manufacturing analytics platform on 14 of its CNC machines to support and inform its continuous improvement strategy.

Co-owner and production manager Andy White says: “We had an ERP in place but no way of accurately measuring jobs and their profitability until they were finished. If a job took longer than expected, we couldn’t see why. FourJaw’s machine monitoring system has given us valuable data that we use to understand machine utilisation, operational efficiency and profitability. In the past 12 months our business has grown from £3.8m to £5m turnover.”

FourJaw’s MachineLink IIoT device is suitable for easy and quick self-installation on any manufacturing machine, regardless of brand, type or age, which makes it suitable for small and medium-sized businesses that prefer a low-cost, no-fuss ‘plug-and-play’ solution. By monitoring and analysing machine data, FourJaw enables manufacturers to make machines run productively and profitably.

“Initially, the guys on the shop floor were a little reluctant but soon became interested to see how it worked,” says White. “It didn’t take long for them to become competitive, wanting to get the best machine efficiency scores, resulting in utilisation going from 75% to 100%. This means that we’re making more products with the same resources, lowering the cost of manufacturing and therefore improving profitability.”

Since installing FourJaw on its machines, the team at Sterling Machining has improved many processes, informed by the platform’s accurate real-time data. For example, the team uses historic data to see how long similar jobs have taken and uses this information to quote more confidently for future work.
For further information www.fourjaw.com

Acquisition leads to record year for Mestec

A UK provider of cloud-based manufacturing execution systems (MES) has posted a record year just 12 months after its acquisition by Eyelit Inc. Bracknell-based Mestec has seen sales grow by over 40% this year, as more manufacturing companies use its solutions to create smarter factories that improve productivity, OEE, quality and compliance.

The business has created more than 15 new jobs because of its growth, with the workforce now totalling 26. Plans are currently in place to grow this figure again over the next 12 months. One of the key drivers for future expansion will come through the footprint of its US-parent and ability to deliver new opportunities in North America.

“We’ve already won our first three pieces of business in that part of the world since the acquisition, which is definitely something we want to build on,” explains general manager Mark Carleton. “Our SaaS-based solution is configured for each client and works best where there is a level of production complexity and compliance required. This has seen us build up strong client bases within the aerospace and defence, automotive, electronics, food and beverage, and medical sectors, delivering operational performance benefits to the likes of Sheffield Forgemasters, Siemens and Thales.”

He continues: “What makes us different is the time we take on the shop floor to understand all the different processes and labour issues, generating a clear picture of where our technology can make a real difference. It allows us to deliver the fastest deployment times in our industry, meaning customers can be enjoying cost and time savings within a matter of weeks/months.”
For further information www.mestec.net

Metalworking fluid guide

Experts from the UK Lubricants Association (UKLA) and HSE have prepared a new good-practice guide for the safe handling and disposal of metalworking fluids. The guide provides advice on how to maintain and control exposure to metalworking fluids in order to prevent ill health, particularly asthma, occupational hypersensitivity pneumonitis and other breathing problems. Work-related asthma is a significant and growing problem with an estimated 1500 to 3000 new cases each year. On average, at least 20 of these cases are associated with exposure to metalworking fluids.
For further information www.bit.ly/43yj6RR