Machinery & Manufacturing | Issue 10 | 2023

HIGHLIGHTING MACHINE TOOL AND MANUFACTURING TECHNOLOGY

HIGHLIGHTING MACHINE TOOL & MANUFACTURING TECHNOLOGY

ISSUE 10 | JULY/AUG 2023

SCAN THE CODE USING YOUR CAMERA APP TO READ THE DIGITAL VERSION

Page 66 ‘Mixed Reality Brand Experience’ Mitsubishi Materials at EMO 2023

WATCH VIDEO

Do we truly understand the apprenticeship experience?

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“Accessible, affordable and achievable automation”

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Show Preview: LET’S TALK COMPOSITES EMO HANNOVER Should bus manufacturers switch to composites?

GRINDING A perfect match for medical

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ProtoTRAK ® now equipped with an automatic toolchanger and more.

The touchscreen, easy-to-use ProtoTRAK ® control has now been

integrated into the fully enclosed, solid ribbed cast iron machine carcass

of our best selling XYZ LR VMC range.

This formidable combination gives new levels of programming and

production capabilities never realised before.

Get the best of both worlds with easy agile programming for

‘

prototypes and one-offs, but now with long run production capabilities

This is a game changer, a formidable pairing and a ‘must see’ for all existing ProtoTRAK ® users.

including automatic tool changes.

Nigel Atherton MANAGING DIRECTOR

XYZ RMX 2-OP

XYZ 500 TMC

XYZ 750 TMC

XYZ 1000 TMC

XYZ 1600 TMC

Mobile CNC

510 x 400 x 450 mm

750 x 440 x 500 mm

1,000 x 500 x 500 mm

1,600 x 660 x 635 mm

Call today to get the full XYZ TMC brochure

TMC ProtoTRAK ® The easy-to-use ProtoTRAK ® control now on a full range of XYZ Machining Centres.

01823 674200 | sales @ xyzmachinetools.com www.xyzmachinetools.com

ProtoTRAK ® Toolroom Machining Centres - the perfect solution for prototypes, one-offs and production.

XYZ TMC Brochure 20pp-1.indd 1

15/03/2022 17:13

Contents 7 Thought : Memo about EMO Bring on EMO Hanover!

Our Team

Publisher - Laura Crawford laura@machineryandmanufacturing.com Contributing Editor - Steed Webzell steed@machineryandmanufacturing.com Circulation Enquiries circulation@machineryandmanufacturing.com Advertising Enquiries hello@machineryandmanufacturing.com Editorial Submissions editorial@machineryandmanufacturing.com

Catch up

What’s been happening?

Celebration of Manufacturing Shearline celebrates 60 years Let’s Talk : Composites Should bus manufacturers switch? The Career Files in discussion with Hannah Linden of JLR The Think Tank : Apprenticeships Do we really understand the experience?

Welcome... Welcome to issue TEN of Machinery & Manufacturing magazine. Crafted by our team of dedicated Engineering Media professionals especially for you, the CNC machine tool intensive manufacturing community. With a passion to support the metalworking & manufacturing sector, we invite you to enjoy an immersive reading experience. This is a hybrid magazine, to be read on or alongside your desktop, phone or tablet. I’m a hybrid! How do you use me? Click or scan the play buttons for instant video Click or scan the download buttons for instant brochure downloads, discreetly appearing on your device in a separate file ready for you to simply hit save.

Training Skills on the shop-floor Show Preview EMO Hannover 2023

Business & Finance Guest writer Anton Nebbe

Published in an eco-aware format by Engineering Media Ltd.

Grinding A perfect match for medical Quality & Inspection Hill Helicopter’s quality takes off

Company Number : 13634129 VAT Registration 397 8226 41 Our registered office address is :

20-22 Wenlock Road, London, N1 7GU Maidstone Office : +44 (0)1622 296112 In our mission towards carbon neutral, we publish and replant in partnership with:

Manufacturing Solutions A conversation with Hyde Engineering Let’s Talk : Robotics Unveiling affordable robotics, from igus Metrology Taking quality control to the next level Tooling Technology Investing in the future of engineering

Book your ticket

Aerospace Machining XYZ takes to the skies

Keep up to date... www.machineryandmanufacturing.com Hungry for more?

© All rights reserved. Machinery & Manufacturing along with it’s contents, should not be copied or transmitted in any format without seeking prior consent from Engineering Media Ltd. You can read our privacy policy by visiting www.machineryandmanufacturing.com where you will find more detail about how we protect your data. The contents of Machinery & Manufacturing does not imply our endorsement, where interviews and articles contain views, they do not necessarily reflect the views of our editors.

Bending Hydraulic systems specialist buys British Sawing Stockholder investment cuts lead times

Supplier Focus On track thanks to Hurco

How time flies when you’re having fun. Yes folks, welcome to the landmark 10th issue of Machinery & Manufacturing. And what an issue it is, with our EMO 2023 exhibition preview taking pride of place. Taking place on 18-23 September in Hanover, Germany, I’m very much looking forward to EMO. After all, it’s the world largest trade show for machine tools, providing the platform for an array of product launches and astonishing displays of metal-cutting and metal-forming excellence. I’ll be among the circa 130,000 visitors at the show, flying the flag for Machinery & Manufacturing and taking note of any exciting new products or technologies that you need to know about. There will certainly be a lot of ground to cover, with around 2,200 exhibitors expected to present their latest innovations. Note to self: pack comfortable shoes. The first EMO took place in 1951, but the 2023 edition will be the first for Machinery & Manufacturing, which produced its first issue in January 2022. Just like today’s machine tools would be unrecognisable to those attending the show in 1951, so the sector’s supporting publications have also evolved. As a hybrid publication, Machinery & Manufacturing offers an immersive reader experience for enjoyment on or alongside your smartphone or tablet. You can click or scan buttons for instant video content or brochure downloads. Similar to the new machine tools on display at EMO 2023, we’re taking trade publications to the next level. In terms of content, Machinery & Manufacturing provides a broad spread of news, technology features, visit reports and interviews, many of which are exclusive to our publication. You simply won’t find them anywhere else. What’s more, as you’ve already discovered, we visit the sector’s major events, keeping you up to date with all the latest tech. EMO here we come! Laura Crawford Laura Crawford, Editorial Director A mEMO about EMO

Catch up

Geely and Renault Group have signed a joint venture agreement to launch a new powertrain technology company that aims to become the global leader in developing, manufacturing, and supplying best-in-class hybrid powertrains and highly efficient ICE powertrain. The initial organization will secure the continuity of the business with two operational centers in charge of the respective operations: Madrid for Renault Group and Hangzhou Bay for Geely. An executive team will be based in Renault Group and Geely sign Joint Venture

New appointment at Warwick Machine Tools

the headquarters of the new company, which is intended to be established in the UK, to consolidate operations, build on synergies, and define future plans.

Warwick Machine Tools (WMT) is excited to announce the recent appointment of Chris Hellyer to the role of Sales Director. Bringing a wealth of machine tools knowledge and experience, especially within the EDM sector, he is looking forward to this next challenge. Chris has been tasked with boosting and building the EDM wire cut and die sinking business for both the Excetek and Zimmer & Kreim (Z&K) brands exclusively represented in the UK and Eire by WMT.

out there, with the Excetek products being so capable, reliable and user friendly I think we will see nothing but growth.” www.warwickmachinetools.co.uk

With the cost-effective Excetek CNC EDM range, as well as the recently announced high specification Z&K range from Germany, Chris Hellyer knows he can offer the customer an ideal solution. “There is no shortage of work Alphacam as Meltio’s Official Sales Partner Alphacam and Meltio; a disruptive laser metal deposition technology manufacturer have announced that alphacam is going to play a key role in the distribution and support of the Meltio metal 3D printing solutions, as an official sales partner. Meltio offers a pioneering metal 3D printing solution that enables industrial applications with a process built around safe, clean and affordable metal feedstock. Alphacam will focus on building a supportive ecosystem for Meltio’s technology, partnering and driving business opportunities alongside technology centers, tooling machine companies, robotic integrators,

More Insight from Mills CNC

The VariMill range of end mills has been a standout performer in the industry for several years with WIDIA continually evolving the industry’s most dynamic range of end mills for high-performance machining. Now, the VariMill series has been improved once again with the arrival of the new VariMill Chip Splitter range that is available from Industrial Tooling Corporation (ITC). www.itc-ltd.co.uk Ferocious 5-Flute Milling

Mills CNC, the exclusive distributor of DN Solutions’ and Zayer machine tools in the UK and Ireland, has just published a new ‘Summer Edition’ of Insight – the company’s popular, customer-facing magazine. Available in digital format and accessed from the company’s website, this latest edition contains a retrospective overview of Mills’ impressive business performance over the last six months, focusing on how it addressed rising demand for its machine

tools and automation systems against a backdrop of macro-economic challenges and supply-side issues. The edition also features articles on the new DN Solutions’ 8“- 10” chuck, box guideway DNT lathe series, introduced into the UK and Irish markets at the start of the year, and the company’s latest social media ‘News & Views’ YouTube video initiative. https://www.millscnc. co.uk/more-insight-from-mills-cnc-2023-07/

Download Now

academia, and industry. https://meltio3d.com

Machinery & Manufacturing

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Machinery & Manufacturing

Catch up

MecWash expands presence

Cimatron powers up version 2024

including multi-view spacing, batch-processing for drawing updates, tangent control for blending faces, and an easy option for capping internal islands. Mold makers gain powerful CAD enhancements for rib construction with added functionality for working on multiple curves in a single operation. Die designers can now easily build 3D drawbead geometry to control material flow during the drawing operation in order to achieve the optimal forming of a part without cracks and wrinkles. Find out more www.cimatron.com/en Manufacturer opens the door to growth A West Midlands based supplier of specialised steel doors has invested £1m in a new sustainable warehouse to help grow and decarbonise its operations, thanks to support from Lloyds Bank. Latham’s Steel Doors is one of the UK’s largest manufacturers of steel security doors, selling its products to customers worldwide from its online store. Due to increasing demand from Europe and America, the firm has decided to invest in a bespoke warehouse, connected to its current premises in Oldbury, Sandwell, just outside of Birmingham. To support the manufacturer with its growth, Lloyds Bank provided £1m worth of funding for the brand- new warehouse via its Clean Growth Financing Initiative. www.lloydsbankinggroup.com

Cimatron, a CAD/CAM software supplier for the mold & die industry has released version 2024 with stronger core capabilities across all areas of the product, while incorporating new technology through collaboration with Sandvik Coromant. Cimatron 2024 simplifies and automates many tasks for tool designers for higher productivity, and more options for digital connection. Efficiency remains a key focus, with a number of advanced user workflow updates

MecWash Systems Ltd. is pleased to announce its new distribution partnership with AQUASGROUP Founded more than 35 years ago, AQUASGROUP is a chemical engineering- based designer and manufacturer of process water purification, treatment, and recycling systems under its trademark Green Factory Series line of equipment. AQUASGROUP also manufactures its trademark Oasis Series Zero Liquid Discharge (ZLD) precision cleaning and metal finishing lines of equipment. In early discussions about a possible partnership, the principles at MecWash and AQUASGROUP discovered how aligned they are regarding closed-loop usage and recycling of water to clean components in industrial

applications. Furthermore, each company’s target markets of aerospace, medical, hydraulics, automotive, electronics and precision engineering overlay almost identically. Hence, this partnership will prove beneficial for both companies immediately and into the future. www.mecwash.co.uk

Raising the profile of manufacturing

Midlands based ‘Marvellous Manufacturing’ CEO Angela Lawlor travelled to Portsmouth on 4th July to deliver two workshops created to inspire secondary school students into careers within the manufacturing industry. The students had the opportunity to learn about Product and Packaging design and were set the task of creating a baked product and designing their packaging to appeal to their target market. They were then asked to plan out their marketing strategy and present their findings. This workshop was funded by Southern University Network (SUN). However ‘Marvelous Manufacturing’ travels to schools around the UK to engage students and teachers alike with the world of manufacturing. Perhaps you are looking to invest in your local talent pool by targeting local secondary and

Youngsters receive the industry’s ‘thumbs up’ for innovation

Challenge’ first prize with a bionic arm brace and rehabilitation glove for people with limited hand and arm mobility. The arm was designed to be worn by a user who could have conditions such as a stroke, paralysis or Parkinson’s disease which inhibits hand and arm mobility. The event saw awards for group category, as well as second and third placed singles. With students entering from all over the UK. Prizes were awarded by Bob Shanks, of this years’ sponsor ‘The Imagineering Foundation’. Mark Wood from Siemens and last years winner Scarlett Ward. Machinery & Manufacturing magazine are proud media partners to the TDI Challenge and congratulate all of the finalists and winners. www.thetdichallenge.co.uk

The Technology, Design and Innovation (TDI) challenge is an annual competition open to 14- 19 year olds, organised by the Manufacturing Technologies Association and again hosted at machine tool manufacturer Yamazaki Mazak’s European HQ in Worcester. Bhavy Metakar, 18, scooped the ‘TDI

post-16 students? If so ‘Marvelous Manufacturing’ create a bespoke workshop and deliver it on behalf of your company providing effortless investment in your local area whilst raising the profile of your business.

Get involved

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Machinery & Manufacturing 10

Catch up

PREMIUM PERFORMANCE CUTTING TOOLS Measurement Report Tool Reference Number: 30-off-diameter Tool Description:

Natwest launches business banking switcher offer for SME’s

4 August 2021 Operator: Laser Type:

Target Parameters Nominal radius

2.9800 2.9800 ±0.0100 5.0 deg 2.0 deg

lc50 mm

Actual radius

Units:

Tolerance

Image Scale:

Start angle OD Start angle EOT

Measurement Summary Maximum positive error

0.0006 -0.0002 0.0000 0.0000 0.0002 -0.0002 0.0001

Maximum negative error

Average error

Absolute average error Average positive error Average negative error

Standard deviation

James Holian, Head of Business Banking at NatWest, said: “As the UK’s biggest bank for business, we hope that businesses will take us up on the offer of two years of free banking to help reduce costs, and gain access to the innovative toolkit of business support we provide to SMEs in the UK. “This new offer builds on the recently announced market-leading 3.56% interest rate on our 95 day notice Savings account. “While a simple switch process will save some money, the true value comes from the breadth of business expertise, insight and support NatWest provides to help SMEs start up, scale up and thrive.”

The new SME switcher offer from NatWest for businesses with up to £2m in turnover comes at a time when customers could benefit from a reduction or break in their banking fees. The new offer is expected to save business customers on average nearly £2,000 over two years, depending on the size of the business turnover and transaction activity. New start-ups opening a bank account for the first time will also get 24 months free business banking when they join NatWest, which is a six-month extension on the previous offering. The offer also extends to businesses who have business banking accounts with multiple providers, who choose to switch all their banking to NatWest.

Measurement Cycle Results

LINEAR CHISEL FOR CENTRE CUTTING

LINE FORM ACCURACY +/-0.002MM

ANCA Pty Ltd 25 Gatwick Road Bayswater North Victoria 3153 Australia

ph: (+61) 3 9751 8200 web: www.anca.com email: ozinfo@anca.com

Page 1

INVISIBLE OD & BALL TRANSITION

SMOOTHER GASH SURFACE

BALL RELIEF AT 45 DEGREES

Cutting tools like ballnose, corner radius, barrel shape ballnose, and double corner radius endmills are widely used in diemold, aerospace, power generation and other industries. The surface finish, quality, accuracy, and runout are critical for performance and cutting life in all applications. The FX ULTRA package includes nanometre or micro degree resolution changes to linear and rotary axis, new servo control algorithms, MTC (Motor Temperature Control), and major mechanical changes. These smoothing parameters provide greater control for the velocity and acceleration/deceleration along with machine jerk limits.

www.natwest.com/business

HY-PRO Additions 2023

OSG are excited to announce the release of their newest brochure, HY-PRO Additions 2023. The additions brochure showcases the latest lineup of cutting-edge products and innovations designed to enhance machining performance and productivity. With a focus on delivering exceptional quality and efficiency, HY-PRO Additions 2023 offers a range of cutting tools and solutions tailored to meet the evolving needs of the manufacturing industry. HY-PRO Additions 2023 brochure not only highlights the latest offerings but also provides technical information, performance data, and application insights to assist

customers in selecting the most suitable tools for their specific requirements. With an understanding that every machining operation is unique, OSG’s goal is to provide tailored solutions that optimize productivity, reduce costs, and maximise tool life.

LESS THAN 0.002MM RUNOUT ON CUTTING EDGE WITH REFERENCE TO SHANK

0.002mm A

https:/ uk.osgeurope.com/

Download brochure

HALL 6, F 52

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Machinery & Manufacturing

Manufacturers celebration

Born in Cambridge, Shearline Precision Engineering is now based in Ely but the reach of its input is not only worldwide but extends to outer space! The company is the power behind a good many thrones and its parts can be found in world-leading inkjet products for Cambridge and other players, innovative medical devices and beauty advancements, F1 motor racing and globally renowned car marques, electric vehicles, electronics, defence, aerospace and nuclear markets. Shearline subsidiary SXL is currently quoting a multi-million-pound package of work for the defence industry – many parts for which will be manufactured from magnesium. One of its ventures is already out of this world. Two freshly engineered Raspberry Pi computers launched for the International Space Station boasted Shearline-made super corrosion resistant cases. Shooting for the stars wasn’t foremost in founder David Littlechild’s thoughts when he borrowed £60 from dad and scraped together some savings to launch the fledgling business from the summerhouse at the bottom of his parents’ garden in Cambridge. Dyslexic and with no qualifications from leaving school, David had learned the trade by working at Cambridge University Engineering Labs. With no prospect of a degree that would have landed a key job at the Department he decided to go it alone. Brother John had introduced him to a glass blowing company called TW Wingents and he started making gas jets for their blow torches on a small lathe in the summerhouse. That work blossomed and in the meantime John and David launched a flash lamp manufacturing business at Cambridge Science Park – Noblelight. David sold his stake and decided to strike out on his own. Shearline steadily picked up

‘£60 startup’ engineers global greatness as it toasts 50th anniversary

An engineering business started for little more than £60 in its founder’s garden shed in 1973 has blossomed into a multimillion-pound concern as world-leading clients steer pioneering technology into major markets globally.

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Manufacturers celebration

In 2007 it bought the company HLT allowing Shearline to machine, scribe and cut ceramics materials. In 2010 it then bought the assets of a motor sports company, now known as Shear XL. Their work includes racing car engines and transmissions and hypercar components. Shearline is also now working closely with a defence customer in the United States machining magnesium components for drones. A rock-solid reputation for high quality components and razor-prompt delivery continues to trigger fresh approaches from new customers. David says: “For example, that US company approached us as they were struggling to find a suitable manufacturer that could machine magnesium, due to its flammable properties.” So now Shearline is working closely with an exciting new customer in the development and manufacture of fast charging battery systems. It is collaborating with a fresh client in the food and drink industry, quoting an innovative environmentally friendly system – a design which has passed recent trials and is rapidly gaining a lot of interest. “This one has the potential to take off in big volumes!” says David. Another subsidiary HLT is partnering with a

skilled staff.

Spurred by government failure to consistently woo enough apprentices into manufacturing industries, Shearline chose to develop its own apprenticeship scheme. This provides high quality apprentices following a four-year programme. Similarly, being aware of the gender disparity in the engineering sector and how important it is to make sure women are fully represented, Shearline always ensures that women form a key element of the annual apprentice intake. Two of the current apprentice cohort are women. In terms of the workforce overall, almost a third of the company’s entire staff are women, several of them talented engineers, while a good number are managers right up to the Finance Director role. Ever mindful of the macro-economic situation, Shearline senses a further opportunity for growth, as David Littlechild explains: “One of the reasons I believe the future for Shearline is so good is that the recent supply chain problems with China has forced companies to consider reshoring their manufacturing operations.” n

Watch the video

David says: “The investment in new machines and the latest technology has been a priority for Shearline and has allowed us to maintain efficiency and quality – both crucially important in global markets. The investment has included one of the largest 5th axis machining centres operating in a sub-con environment.” Paying it forward has, in turn, paid dividends, as Shearline continues to expand into new markets. For example, the company has AS9100 accreditation to supply parts for the aerospace and defence industries. Some of the newer markets it services include Robotics, Wind Turbines, EV technology, medical and Electron microscopes. “The investment in new machines and the latest technology has been a priority for Shearline and has allowed us to maintain efficiency and quality.”

https:/ shearline.co.uk

global manufacturer in the electronics industry and running trials with a view to start manufacturing in production volumes at the start of next year. Demonstrating its versatility, Shearline is working on a prototype fabricated aesthetic beauty device for an extremely well-known household name company. Shearline is now reaping the gain but it has not been without pain. David – who these days acts in a consultancy capacity – and managing director Jon Littlechild say one of the biggest challenges has been finding suitably

work from globally successful companies and shifted through the gears in terms of premises before building its own showcase facility in Ely. The biggest growth factor was a contract with instrumentation giant LKB Biochrom which has remained a customer for more than 45 years. Another catalyst for expansion was the development of the inkjet sector, principally through Domino, Linx and Willett (now Videojet) – all of whom are customers today. Shearline has consistently invested large sums in state-of-the-art machinery which, in turn, boosted capability and meant Shearline could handle increasingly large and complex jobs.

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Lets talk : Composites

Many bus and coach manufacturers favor using traditional materials like extruded aluminum profiles rather than composites because of the lower upfront cost and because it’s what they have been comfortable using. However, with an increasing focus on sustainable products, composites can provide bus operators with advantages by delivering improved integrated design possibilities and reducing lifetime maintenance costs. Here John Mertic, area sales manager at bus and coach composite profile manufacturer Exel Composites, discusses the key benefits of using composite profiles in bus and coach manufacturing compared to aluminum profiles. Should bus manufacturers switch to composites?

Watch the video

Using continuous manufacturing processes

Furthermore, composites also bring the additional benefit of being corrosion and rust resistant, meaning they can withstand pollution or salty road conditions unlike aluminum surfaces, which corrode over time and require regular maintenance. Fiberglass composite profiles are also significantly lighter in weight than comparative metal profiles, which means buses and coaches fitted with composite parts have an opportunity to increase fuel efficiency and, thus, lower carbon emissions. The weight saving is particularly beneficial after increases in global fuel prices, particularly for diesel, as this leads to increased fuel efficiency and lower overall fuel costs for businesses. As the industry moves away from fossil fuels towards electrification, the weight savings will also support longer electrical autonomy in buses and coaches. The composite market is much more stable than the metals market, with less volatile pricing and more predictable lead times. Manufacturers that use large volumes of steel or aluminum are at the mercy of market conditions and, in recent times, the geopolitical environment, often not knowing the exact price or lead time for parts until they place their orders. This causes a risk of supply chain disruption for bus and coach manufacturers and also impacts profitability.

Exel Composites specializes in pultrusion and pull-winding, which are continuous manufacturing processes that are well suited for high-quality, high-volume production. These enable it to provide large composite profiles that have consistent production quality batch-to- batch and are highly repeatable. In the pultrusion process, strands of glass or carbon fibers, mats and/or technical fabrics are pulled together, saturated with resin, and then pulled into guides that feed into a heated die to cure the composite in a process called thermosetting. This profile can then be cut to the desired length. This manufacturing method supports the increased flexibility options discussed previously. For example, it allows manufacturers to add additional reinforcement fibers to only one part of the profile where it is needed, so there are no wasted fibers or unnecessary additional weight. All these advantages mean fiber reinforced composites could hold the key for forward- thinking bus and coach manufacturers looking to construct lighter, more efficient vehicle bodies that offer long service lives and reduce ongoing maintenance costs. To find out more, visit https:// exelcomposites.com/composite-solutions/ composites-in-transportation/bus-and-coach- profiles/ n

Composite profiles, in this case fiberglass, can be integrated in most sections of a bus or coach where aluminum profiles are usually found. This includes internal profiles, such as handrails, luggage supports, air ducts, and external profiles, such as cant rails, skirts, and paneling. Replacing traditional material

in size. This means installation, replacement, and maintenance of composite panels is a faster, simpler, and a less labor- intensive process compared to using aluminum. Composite profiles can also come equipped with a peel-ply surface that is applied during the composites’ manufacturing

process, creating a surface that remains

profiles used in bus and coach manufacturing with composite profiles provides several key advantages, resulting in a reduced total cost of ownership for businesses, despite sometimes having a higher upfront cost. Reducing cost of ownership Composites do not have the same maximum width issues as aluminum, meaning composite bus panels can be produced in one continuous profile as opposed to multiple narrower panels joined together to reach the same width. Composite profiles can be up to 1.6 m wide (63 inches), while aluminum profiles are more limited

clean and ready for bonding. Bonding composites to the bus in this way eliminates the need for additional rivets and screws and further reduces labor requirements. Composite profiles come with enhanced design flexibility options in terms of their profile geometry compared to traditional metal profiles. This allows manufacturers to produce a single complex profile that incorporates the functions of multiple traditional aluminum parts, resulting in a more elegant design that is simple to produce, requires less assembly work, and provides fewer opportunities for human error during installation.

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The Career Files

Contributing Editor Steed Webzell speaks with Hannah Linden, a second- year metrology apprentice at JLR, who is already spending her days programming robots “At school I didn’t really have any idea about what I wanted to do,” states Hannah Linden, probably speaking for many youngsters who feel a little lost when it comes to making career decisions. She ultimately ended up studying A-Level Art & Design before getting a steer from a familiar ally, her dad, himself a successful engineer and former apprentice. “My dad suggested I apply for an apprenticeship and it was the best decision I ever made.” Hannah began as an engineering and manufacturing apprentice with Make UK, before securing a placement at Jaguar Land Rover (JLR), where she is currently a second-year apprentice specialising in metrology. She has part-time college release, working towards her BTEC and NVQ Level III qualifications. “Metrology sounded really interesting and I wanted to challenge myself,” Hannah explains. “I selected metrology from a list that also included maintenance, tool room and site services.” Working at JLR’s Pilot Plant next to the company’s landmark Castle Bromwich facility, Hannah spends her days performing and learning about numerous advanced technologies, a case in point being a new automated scanning system. Made to measure Hannah Linden, Jaguar Land Rover

“Essentially two robots move up and down a cell, scanning and capturing images of cars and components,” she says. “I’m in a group with two colleagues, challenged with becoming the team responsible for the application of this system. I program the robots, load the part requiring measurement – maybe an underbody, battery tray or even a complete car – before completing the scan and retrieving the required data. We then generate reports for the engineers.” Hannah is one of three apprentice metrology engineers on site, two of whom are female, and she is keen on encouraging other students – of both genders – down the apprentice route. “I regularly volunteer to take part in school careers events, giving advice to students. I always say please don’t ignore apprenticeships and think university is the only way forward. I’m living proof that an apprenticeship can give you so many opportunities. As a second-year apprentice I never thought I’d be here, spending my days programming robots.” n “I’m living proof that an apprenticeship can give you so many opportunities”

Owning a Mitutoyo CMM comes with a lot more than you may think!

The initial expense of a CMM is only part of its lifecycle cost. Superior build quality delivers higher reliability and greater performance enabling more throughput, thereby reducing the total cost of ownership. A Mitutoyo CMM offers exceptional performance, the highest accuracy and a solid upgrade path for future innovation. Backed by industry leading software, comprehensive training and optional service maintenance contracts for peace of mind.

Scan here for further information or visit www.mitutoyo.co.uk/cmm-technology

Machinery & Manufacturing 20

The Think Tank Apprentices

The Think Tank

Do we truly understand the apprenticeship experience?

Recent Government figures show that almost half of all Apprentices (47 per cent) are now dropping out of their course. So what is the answer to retain these talented youngsters?

According to a recent EDSK report by FE News, for many Apprentices a poor experience ‘in company’ is the main factor for them leaving their Apprenticeship, with employers cited as treating Apprentices as workers rather than learners. With an annual shortfall of over 186,000 young engineers every year, a shortage of skilled workers and an increase in the number of engineering firms looking to start or scale Apprenticeship schemes; it is vital that the engineering and manufacturing industry ‘gets Apprenticeships right’. But as a sector how can we better understand what factors contribute to a

great Apprentice experience? One where the Apprentices are not only retained but become evangelists to others in their age group to join them within the industry or in their company. That is the question that Next Gen Makers recently put to a group of Engineering Apprentices during a round table discussion at the Make UK Technology Hub in Aston, Birmingham. Apprentices involved represented companies including Veolia Water Technologies, Collins Aerospace, Severn Trent, Seco Tools and Ishida Europe. As you can imagine, it was a passionate discussion, from a diverse group that are keen to

“All Apprentices had the opportunity to rank what matters most to them from a choice of nine options, with regards to their experience as an Apprentice”

see more young people follow in their footsteps as the next generation of engineers. All Apprentices had the opportunity to rank what matters most to them from a choice of nine options, with regards to their experience as an Apprentice – with Next Gen Makers tallying up the responses for each to determine a ranked score. ‘Developing new skills’ was the most important element of their Apprenticeship, as voted for by the Apprentices. ‘Progression opportunities’ came second, followed by ‘Achievements being recognised’, which completed the top three. ‘Feeling valued’, ‘being able to visit other departments and learn other areas of the business’ and ‘getting on with co-workers’ were the fourth, fifth and sixth most important factors contributing to a great Apprentice

experience.

Finally, the three least important factors contributing to making a great Apprentice experience were ‘having a Mentor’ in seventh, ‘feeling included’ in eighth and ‘pay’, which came last as far as these Apprentices were concerned. That is not to say that these factors are unimportant, they were simply deemed less

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Represented by

The Think Tank Apprentices

INNOVATIVE ENGINEERING SOLUTIONS

important a contributor to their satisfaction with their Apprenticeship than the other options. From Next Gen Makers’ work running the Make UK backed Engineering Apprenticeships: Best Practice Programme, we know from speaking with hundreds of UK manufacturing firms that the ability to create a great Apprentice experience differs widely across UK industry. It is a complex combination of multiple components, all of which add up to define the experience of an individual, as lived by them. The Make UK Engineering Apprenticeships: Employer Kitemark accreditation, achieved via the Engineering Apprenticeships: Best Practice Programme, involves recognising exemplar employers of Engineering Apprentices – the kind of employers that go the extra mile in creating a great Apprentice experience and investing in the ongoing learning and development of their Apprentices. The accreditation includes three components: benchmarking (self-reflection and continuous improvement with regards to the set up and operation of the company’s Apprenticeship scheme), an Apprentice satisfaction survey and a Training Provider survey, to gain the perspective of the Training Provider with regards to how the company runs its’ Apprenticeship Scheme. 80% of the Kitemark scoring is attributed to the Apprentice “It is a complex combination of multiple components, all of which add up to define the experience of an individual, as lived by them”

satisfaction survey. The Apprentice satisfaction survey includes a robust question set of 20 questions which encompass the Apprentices’ experience to date, their wellbeing and their training and development. Ultimately, for the employer this is providing a comprehensive and personalised layer of insight directly from their Apprentices regarding their experience within the business, which in turn helps the company to better evaluate and improve their Apprentice experience and their Apprenticeship Scheme. We are seeing an increasing number of companies establishing Apprentice counsels, or providing new ways for their Apprentices to feed back ideas and giving them more time with senior figures within the business. The feedback from all of this, is Apprentices feeling more valued and recognised, something which is leading to greater retention of those individuals not only within the Apprenticeship scheme, but within the business over a longer period of time. n

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Machinery & Manufacturing 24

Business & finance

BSI scores – June 2020 to May 2023

A CAUTIOUS RETURN TO CONFIDENCE for Manufacturing and Engineering SMEs

Research date BSI score UK

BSI score Manufacturing and Engineering

May 2023 December 2022 July 2022 February 2022 September 2021 April 2021 November 2020 June 2020

26.5

11.5 14.25

12.5

18.25

27.9

38 40.5 37

31.75

28.63

14.5

20.25

12.25

Appetite for investment Overall, the appetite to invest remains strong, as it was at the end of 2022, with 83% (UK: 75%) of Manufacturing and Engineering firms looking to seek funding for investment in the next 12 months.

By Guest Writer Anton Nebbe, Head of PR and Communications, Close Brothers Asset Finance

Q: Does your business plan to seek funding for business investment in the next 12 months?

A few years ago, I developed – along with a statistician at the Manufacturing and Technologies Association – a confidence tracker for small to medium sized businesses, which we called the Business Sentiment Index. The score we calculate is based on four key indices (see bottom of this piece), and measures how business owners are feeling at a certain point of time.

Manufacturing and Engineering

May 2023

Yes 75% No 25% Yes 76% No 24%

Yes 83%

No 17%

December 2022

Yes 83%

No 17%

The score for Manufacturing and Engineering typically tracks higher than the UK as a whole, and generally outperforms other sectors, including Construction and Transport, for example. What we found the last time we conducted our research in May 2023 is that business confidence across all sectors – including Manufacturing & Engineering - rose for the first time since September 2021, following three consecutive falls and a low at the end of 2022. These were caused, in the main, by rising inflation, energy cost increases and higher interest rates. Despite the headwinds still being faced

by small and medium-sized firms and inflation stubbornly remaining in double digits, wholesale energy prices have fallen from their summer 2022 peaks, and there appears to be more certainty about where interest rates rises are headed, all of which is helping firms plan with more assurance. This change in confidence is better understood when looking more closely at Manufacturing and Engineering businesses’ priorities, which are managing costs (29%; UK: 26%) and achieving growth (22%; UK: 28%) well ahead of issues like paying down debts (10%; UK: 9%) and business consolidation (9%; UK: 9%).

Missed opportunities The number of Manufacturing and Engineering companies that have missed business opportunities because of a lack of available funding stands at 47% (UK: 45%) in May 2023. While this is an improvement, these are historically ‘high’ figures – for example, in May 2022, 37% of UK respondents answered ‘yes’ to the question ‘have you missed a business opportunity in the last 12 months, due to lack of available finance?’.

It would appear businesses are concerned about impacting their cashflow by dipping into their reserves or taking out a standard loan and adding to their debt burden. Q: Have you missed a business opportunity in the last 12 months, due to lack of available finance?

Manufacturing and Engineering

Yes 45% No 55%

Yes 47% No 53%

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Business & finance

Economic outlook Manufacturing and Engineering businesses are more positive than negative about the macro-economic outlook, ‘outperforming’ the consolidated UK sentiment. Compared to the end of 2022, firms in the sector are considerably

more optimistic than they were.

The Best is Now BETTER

This indicator has contributed most to the decline in the overall BSI; for example, in November 2021 75% of respondents were positive about the economy – by December 2022 this had fallen to just 38%.

There won’t be a significant change

Confident economy will grow

Concerned economy will slow

Manufacturing and Engineering

May 2023 December 2022

43%

46% 11% 55% 9%

43% 8% 55% 7%

49%

36%

38%

Predicted business performance Predictions about future business performance remained stable, with the majority expecting their prospects to remain unchanged. Overall,

fewer firms predict they will contract than earlier in the year (7% against 11%). Q: In general, how do you expect your business to perform over the next 12 months?

Expand

Stay the same

Contract

Close down

Manufacturing and Engineering

May 2023 December 2022

34% 1% 30% 54% 15% 1% 55% 10%

37% 54% 7% 1% 36% 52% 11% 1%

When I spoke with Steve Gee, CEO of our Industrial Equipment Division, he had this to say: “After well over a year of declining confidence – according to our data - it’s encouraging to see an element of positivity returning to the market, no matter how tentative. “What business owners want, almost more than anything, is an element of consistency, which gives them the ability to plan and forecast effectively. Many of the recent challenges have been entirely unexpected, and after the difficulties of the past few years, it’s impacted their ability to grow. “But what it has again demonstrated is the continued resilience of the UK and Ireland’s SMEs, and we’re looking forward to working with them in the coming months and years.”

Score calculation* The BSI is based on the views of more than 900 business owners and senior members of the UK’s business community and calculated from data charting their: l Appetite for investment in their business in the coming 12 months l Access to finance and whether they’ve missed a business opportunity through lack of available finance l Views about the UK’s economic outlook l Thoughts on their likely performance in the coming 12 months

Machinery & Manufacturing 28

www.iscar.com

Quality and inspection

company call this approach General Aviation 2.0. General Aviation 2.0 (GA2.0) extends far beyond the aircraft. It represents an end-to-end ownership experience delivering the aircraft customers have always wanted and combining it with all the support needed to get the best out of private aviation. Dr Jason Hill, founder and CEO of Hill Helicopters recently unveiled the HX50, a new UK-built, five-seat, turbine-powered helicopter concept. To enable the extremely efficient, high-precision surface and contour inspection of its in-house manufactured components Hill Helicopters recently purchased a SURFCOM NEX 240 DX-13 from ACCRETECH UK. Explaining the reason for the recently installed machine, Mark Webb, Lead Production Engineer at Hill Helicopters said “Hill Helicopter literature describes the HX50 as delivering of a whole new experience in safety, performance, adventure, comfort and elegance. It isn’t a

Hill Helicopters quality ‘takes-off’ Given the extremely competitive environment global aerospace manufacturers operate within, as well as ensuring the precision capabilities of their quality control equipment, the speed and operational efficiency of the sector’s inspection aids are becoming ever more important.

The recent installation of an ACCRETECH SURFCOM NEX surface and contour measuring machine at the premises of Hill Helicopters illustrates the advantages aerospace manufacturers gain when they are able to achieve rapid, high-precision inspection results. Staffordshire based Hill Helicopters has pioneered a reimagined approach to delivering and supporting safe, exciting luxury private aircraft ownership at an affordable price. The

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Machinery & Manufacturing 30

Quality and inspection

to purchase further SURFCOM NEX machines for use on our shopfloor. Given the SURFCOM NEX’s ability to provide high-precision surface and contour measuring results within production environments, it will be ideal for inspecting components throughout our production runs and for generating and archiving FAIRs (first article inspection reports). “As each of our helicopters have 38 different high-precision bearings, our SURFCOM NEX machines will be used to inspect the critical surface and contour specifications of all of our manufactured bearings. In addition, they will be used on all other relevant in-house produced components. The impressive operational speed and ease of use of our first SURFCOM NEX and that of our planned additional models means that they will be able to keep pace with our high- precision surface and contour inspection needs as our production volumes continue to grow.” Building on the global success of the company’s previous SURFCOM product, the recently launched ACCRETECH SURFCOM NEX range is currently exceeding all anticipated sales projections. Rather than invest in two expensive, dedicated machines, cutting-edge SURFCOM NEX models allows users to achieve high- precision surface and contour measurements by the use of a single, cost-effective instrument. Moreover, as well as occupying much less space than two separate machines, the highly efficient new range delivers up to 60% faster measurement processes’. Given the growing trend for component inspection to take place close to the point of manufacture, in addition to being ideal for use within pristine, temperature controlled cleanrooms, due to their ability to deliver accurate results across a range of temperatures, the robust SURFCOM NEX range can also be employed within serial production environments. The new range’s innovations include

the use of a flexible hybrid detector that allow simultaneous contour and surface measurements to be made. Rather than use a traditional ball-screw assembly SURFCOM NEX machines employs a progressive linear drive system that ensures rapid, low-oscillation measurements with no disruptive noises and vibrations. Much of the success of the new range is based on the machines’ flexible modular platform. Rather than settle for a surface and contour measuring instrument that represents a near match for their requirements, potential customers are now able to specify a system that exactly meets their own specific needs. For example, the Hill Helicopters’ SURFCOM NEX 240 DX- 13 machine was supplied with two separate detectors. In addition to an advanced hybrid detector that allows simultaneous high-precision contour and roughness measurements to be made in single pass, the DX-13 variant also boasts a high-resolution contour detector that provides an upwards and downwards measuring bias.

Tim Wood, ACCRETECH SBS Regional Director North Europe concluded. “ACCRETECH products enable the high-precision tactile and non-contact measurement of component’s surface roughness and profiles. Features able to be inspected include the measurement of roundness, flatness, levelness, concentricity, coaxiality, axial run-out, radial run-out, perpendicularity, cylindricity, parallelism and straightness. “Thanks to their modular construction, our advanced test equipment can be adapted to meet individual clients’ specific requirements. As Hill Helicopters had several alternative suppliers to choose from, we were delighted to receive an order for a generous capacity SURFCOM NEX 240 DX-13 machine. This option has a 700mm x 450mm granite bed and a column with 450mm of travel. To further aid precision, the Hill Helicopters 240 DX-13 model was also supplied with an integrated anti-vibration table.” n

coincident that ‘safety’ comes first on this list of attributes. To ensure the highest safety standards we oversee a rigorous company-wide quality regime. In addition to employing skilled quality personnel, we invest in the best available inspection equipment. “The latest addition to our impressive list of inspection aids is our advanced SURFCOM NEX 240 DX-13. After searching for a high- precision, rapid-acting surface and contour measuring instrument we concluded that the advanced ACCRETECH machine best met our demanding accuracy and efficiency standards. In addition to the performance of the instrument, ACCRETECH’s reputation for producing high- quality machines, and for providing excellent levels of customer service, were major factors in our decision. “During the development and testing of our components our new ACCRETECH machine will be used by our skilled machinists and our production and quality engineers. Then, when we move into full production, we plan

www.accretech.eu/en

Watch the video

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