Manufacturing and Engineering Magazine Issue 410

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ISSUE 410

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MANUFACTURING AND ENGINEERING MAGAZINE

M M MANUFACTURING AND ENGINEERING MAGAZINE

ADS GROUP A UNITED VOICE

PLUS:

We take a look at Foster Wheeler which has built a reputation for delivering high quality, reliable, technically advanced energy and industrial infrastructure and facilities.

ISSUE 410

GKN AEROSPACE We take a look at GKN Aerospace manufacturer and designer of complex, high-performance integrated metallic and composite assemblies for aerostructures and engine products

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BOWYER ENGINEERING Knowledge and expertise in precision engineering has been passed through Bowyer Engineering for over 65 years.

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ALSO INSIDE...

4Fluor 4KBR Infrastructure 4BCECA 4SMMT 4Achilles ...Plus much more

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Comment editor’s

ISSUE 410

www.memuk.org

The good, the bad and the sort-of okay

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hen it comes to delivering bad news, it’s always better to have something positive to say afterwards. That might not always be possible. In which case, it’s probably best to keep my mouth shut. Of course, this month I was reading along with everyone else that the UK’s manufacturing growth had slowed, which is similar to the rest of Europe. That’s the bad

Magazine Manager Daniel Beardsley Feature Managers Tom Waite Elliott Jenkinson Daniel Duggan Group Editor Daniel Stephens Editor Ciaran Jarosz

news, by the way.

The economy has picked up and we are out of recession but for the first time in over a year, orders

contracted thanks to a decrease in demand both in the UK and abroad. Factories also cut prices in August for the first time since April with euro zone inflation slowing to its lowest rate since the height of the financial crisis.

The European Central Bank has its work cut out to bring low inflation back up to its target of just below 2% given the possibility of a market entering stagnation. This probably means even more affordable lending packages to help inject momentum in the market. This would certainly be positive news for those looking to invest while manufacturers bide their time awaiting a market boost.

But in terms of the worldwide market, things are looking far more positive perhaps suggesting this is just a blip in the road to recovery for Europe. For example, in India, Mahindra & Mahindra Ltd. (M&M Ltd.), India’s leading SUV manufacturer, has reported month-on-month sales increases, registering a huge 4% growth in September.

Similarly, in the US, 213,000 jobs were created in September in the private sector. Indeed, the highest amount of recruitment took place in the manufacturing sector with more than 35,000 jobs created. Small businesses increased their number of staff by 88,000, large businesses by 77,000 and medium-sized ones by 48,000.

However, there was encouragement closer to home as well. Carpet manufacturer Victoria has

Contributors Jeff senior Art Director Steve Williams Art Editor Stacey Brewer Designer Carla Taylor Production Vicki Lindsay Lisa Pollinger Lisa Barrans Accounts Nick Charalambous Manufacturing and Engineering Magazine is published by: Trafalgar Publishing Ltd, 6th Floor, Crown House, Southgate, Huddersfield, HD1 1DE Tel: 01484 437300

strengthened its portfolio with the acquisition of a Yorkshire-based rival in a deal worth more than £7.6m. The deal was a first for the Business Growth Fund which supported the deal with a £10m investment programme. The Fund was set up to help Britain’s developing businesses secure the funding needed for expansion. It appears it is now making the right moves to help UK business move in the right direction!

Daniel Stephens Group Editor

Manufacturing and Engineering magazine is published by Trafalgar Publishing Ltd. Company registered in England & Wales. All material is the copyright of Trafalgar Publishing Ltd. All rights reserved. Manufacturing and Engineering magazine is the property of Trafalgar Publishing Ltd. This publication may not be reproduced or transmitted in any form whole or part without the written permission of a director of Trafalgar Publishing Ltd. Liability: while every care is taken in the preparation of this magazine, the publishers cannot be held responsible for the accuracy of information herein, or any consequence arising from it. In the case of company or product reviews or comments, these have been based upon the true and honest opinion of the Editor at the time of going to press.

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Contents

ISSUE 410

SECTIONS

www.memuk.org

TRANSPORT

8 TRANSPORT 22 MANUFACTURING AND ENGINEERING 36 ENERGY & ENVIRONMENT

ASSOCIATIONS 8 ADS GROUP

The premier trade organisation advancing the UK aerospace, defence, security and space industries.

20 SMMT

Mike Hawes, Chief Executive of The SMMT takes a look at the UK’s thriving and diverse automotive industry.

36 BCECA

BCECA is the trade association representing some of the principal companies in the UK.

47 ACHILLES

Achilles creates and manages a global network of collaborative industry communities.

50 EIC

The EIC provides one of the most comprehensive sources of energy projects and business intelligence in the energy sector today.

REGULARS 4 UPDATE

The latest news from the industry.

52 LOOKING BACK AT..

12 GKN AEROSPACE MANUFACTURING AND ENGINEERING

...Ada Lovelace, the first computer programmer

27 BOWYER ENGINEERING 2

MANUFACTURING AND ENGINEERING MAGAZINE

22 JENKS & CATTELL

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20 SMMT

8 ADS GROUP

FEATURES 12 GKN AEROSPACE

ENERGY AND ENVIRONMENT

GKN design and manufacture high-performance and integrated metalic and composite assemblies.

47 ACHILLES

22 JENKS & CATTELL ENGINEERING

Jenks and Cattell consistently produce high quality metal presswork, welded assemblies and fabrications.

27 BOWYER ENGINEERING

Knowledge and expertise has been passed through this family run business for 65 years.

34 DENHOLM REES & O’DONNELL

41 FLUOR

Denholm Rees & O’Donnell offer a precision engineering manufacturing service.

38 FOSTER WHEELER

38 FOSTER WHEELER

A reputation for delivering high quality, reliable, technically advanced energy and industrial infrastructure and facilities.

41 FLUOR

Working with governments and clients around the world to design, construct, and maintain complex and challenging capital projects.

44 KBR INFRASTRUCTURE

KBR works alongside clientsworldwide to deliver any project, any time, any place.

IN THE NEXT

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M M AIRBUS GROUP | TATA STEEL EUROMOTIVE | SURETANK...

AND MUCH MORE...

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UPDATE

£8 million to train the next nuclear workforce BUSINESS Secretary Vince Cable has announced £8 million of funding to train the next generation of nuclear technicians and engineers.

The funding will create hundreds of new apprenticeships and traineeships as part of the Magnox led Nuclear Industrial Partnership.

Funding builds on the government’s Nuclear Industrial Strategy which is aimed at making sure Britain can benefit from the £930 billion being invested in the nuclear industry over the next 2 decades. The construction of new power plants, alone, could create as many as 40,000 new jobs in the UK. The Business Secretary is making the announcement this morning at the Dungeness plant while on a tour of Kent businesses.

Alongside a visit to Magnox, Dr Cable is to meet pupils from the Langton Star Centre, visit manufacturing firms Integrated Technologies and Geku and will preview the Jasmin Vardimon Company’s latest dance production ahead of the company embarking on its world tour.

Business Secretary Vince Cable said: Today we’ve put our money where our mouth is. Industry has told us they need more skilled workers for the nuclear sector, so this £8 million will help guarantee the next generation of workers. This is part of our work to rebalance the economy, creating jobs across the UK.

Public want more British-made products A RECENT YouGov survey has revealed that the British public want to see more products manufactured and exported by ‘home-grown’ companies. The research found that 59% of consumers want to see British companies manufacturing more, with 64% per calling for an increase in exports. In response to this survey, the EEF called for political leaders to ‘re-balance’ the UK economy.

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Lee Hopley, the EEF’s chief economist, said: “The message to parties and political leaders is loud and clear: a strong re-balanced economy has to be the long-term end goal.

Industry and voters are ‘singing from the same hymn sheet’; we want a robust, stable and resilient economy with a clear focus on balanced growth. This is a message that the party leaders must take into the General Election and beyond.”

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UPDATE IN BRIEF ◆ Lufthansa has placed an order with Airbus for 25 aircraft — 10 A320ceo passenger jets for its low-cost business Eurowings and 15 for its subsidiary Swiss, which is the national airline of Switzerland.

UK large-scale solar projects pairing SOLAR-ENERGY manufacturer SunEdison and global renewable-energy company TerraForm Power have announced the interconnection of two large-scale solar-power projects totalling 50MW in the UK. These projects will become part of TerraForm Power’s operating portfolio before the end of 2014, and SunEdison will continue to manage them.

Carlos Domenech, president and chief executive officer of TerraForm Power, said: “SunEdison can accelerate the growth of its global pipeline with the knowledge that Terra-Form will allow them to benefit from

long-term ownership. As SunEdison’s projects come on-line, we are well positioned to acquire them and generate increased dividends for our investors.”

Once operational, the solar-power plants will be managed by the SunEdison Renewable Operation Center (ROC), which provides global 24/7 monitoring services. Data collected from the ROC is used to continuously improve the company’s products, project designs and service offerings. The energy produced from the projects will be purchased by Statkraft.

Deep Sea Mooring wins contract with Repsol GLOBAL energy company Repsol has selected Deep Sea Mooring (DSM) to provide a range of mooring services for their drilling operations on the Norwegian Continental Shelf.

DSM will be responsible for marine engineering and supplying the mooring equipment. The company will also assist in offshore operations, including both pre-lay and rig move. Åge Straume, CEO of Deep Sea Mooring said: “Winning this contract further proves that major energy companies appreciate our experience, robust technology and competence in delivering complete mooring systems for the harsh environment of the North Sea.” He added that this was the first time the two companies have worked together: “It’s

always exciting to showcase our expertise with a new client and we look forward to developing a solid and long-term partnership with Repsol.”

The framework agreement is set to commence immediately and last four years including options. Deep Sea Mooring will manage the contract from its headquarters in Bergen.

Deep Sea Mooring Group is a Bergen-based global provider of mooring solutions, which it offers through its wholly owned subsidiaries, Deep Sea Mooring and Deep Sea Installation.

Deep Sea Mooring Group is owned by the private equity oil and gas specialist, HitecVision.

◆ Vauxhall’s all-new 2.0-litre CDTi diesel engine has made its debut at the 2014 Paris Motor Show.

The new unit will be revealed in the Insignia and Zafria Tourer as Vauxhall continues the roll out of its new powertrain portfolio. The new engine replaces the current 2.0 CDTi (163PS) engine at the top of Vauxhall's diesel range. ◆ AGL Energy Ltd has welcomed the release of the New South Wales (NSW) Chief Scientist and Engineer’s report on coalbed methane (CBM) activities.

The report stressed that the risks associated with CBM could be managed, and that CBM extraction was no more dangerous than any other extractive industry. ◆ Energy utility SSE has announced that it has secured a six year gas supply deal with Norwegian oil and gas giant Statoil.

The 500,000 therms per day gas deal represents 6 per cent of SSE’s average daily gas demand and falls within a wider procurement portfolio including investment in fuel production and participation in wholesale gas markets. ◆ Reading-based Moo Free Limited, a manufacturer of dairy free and gluten free chocolate, is to invest in new machinery and increase staff by 20 per cent after securing £530,000 in funding from Santander Corporate & Commercial.

The family business has seen strong demand for its specialist products from its primarily dairy-intolerant consumer base, and is looking to invest for future growth. ◆ Siemens Financial Services is extending its asset financing to the company's full range of industrial automation and management software.

The automation giant says its initiative aims to meet the growing demand from industrial organisations for manufacturing systems finance, where software, hardware and services are integrated into a single flexible package.

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UPDATE

Encouraging girls into engineering THE CRITICAL point at which women are lost to a potential career in engineering is at the age of 16, when the A-level and vocational subject choices are made, according to a report from the Institute for Public Policy Research (IPPR) think tank.

The Women in engineering: Fixing the talent pipeline report says that subject choices at 16 are made on the basis of attitudes and perceptions about engineering that have been formed over many years. It also highlights that family encouragement and knowledge of engineering and engineering careers are important in shaping science aspirations, with 68% of young people aged 11-14 saying that they were influenced by their parents ‘a lot’ when it came to career choice.

The BP-supported report also points to the structure of education for 14-19-year-olds in England, which encourages early subject specialisation but does not prepare enough students for higher level technician and graduate studies in engineering.

The report found that in 2013 only one in five physics A-level

entries were female, only two in five mathematics A-level students were female, and just over 72,000 girls achieved grades A*-C in GCSE physics but only about 10% of these girls went on to pursue physics at A-level.

In 2012/13 one in six (17%) engineering and technology students were female at an undergraduate level, the report added.

Dalia Ben-Galim, IPPR associate director, said: “To better understand the significant shortage of women in engineering, it is important to map out where women, sometimes unknowingly, opt out of engineering career pathways. A large part of the problem is that at the age of 16, many girls remove themselves, which suggests the narrowing of the engineering talent pool starts well before people choose a career.

“Misconceptions about engineering continue to influence who pursues a career in this field.

Engineering is still considered by many as a ‘man’s job’, and is associated with a workplace culture that may put off

prospective female workers. To help overcome these barriers in attracting greater female talent to engineering government, schools and business all have a role to play in influencing career choices, and aspirations – particularly at the critical point where school subject choices are made."

She added: “The discrepancy between the number of engineers the UK’s higher education system produces, and how many we need annually shows the UK has a long way to go to fill this potential skills gap.

The most effective way to begin to address this gap is to tackle the low uptake of engineering degrees by women, and, further down the line, the continuation into long-term engineering careers.”

The report recommends that the government should invest in equality and inclusion training for teachers taken as part of their teacher training course and should also be offered as part of continuing professional development.

UK manufacturers 'want to stay in EU', poll finds BRITAIN’S manufacturers are overwhelmingly in favour of the country remaining a part of the European Union, a survey suggests.

The manufacturers’ organisation EEF found that 85% of those it polled would vote to stay in the EU, and only 7% would opt to leave, despite the bloc's economic troubles.

Firms with more than 250 employees were most keen on the EU, with 90% saying they would want to retain membership.

The survey, carried out in August, included 160 companies.

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Manufacturing companies in both the UK and the wider EU have been suffering in recent months.

Two surveys carried out in August showed that growth in the UK manufacturing sector has slowed, with both new orders and output increasing less rapidly than before.

The Markit/CIPS UK Manufacturing Purchasing Managers’ Index (PMI) edged down in August to 52.5 from 54.8 in July, its lowest reading for 14 months.

Meanwhile, manufacturing across the

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eurozone fell in September to a PMI reading of 50.5, the lowest measure since July of last year.

Commenting on the EEF poll’s findings, chief executive Terry Scuoler, said: “Despite the continued problems in the eurozone, manufacturers remain overwhelmingly of the view that our economic wellbeing is inextricably linked to the EU and, we must stay in membership.

“It makes no sense to disengage from our major market and it remains fanciful to think we can just pull up the drawbridge and walk away with no consequences.”

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UPDATE

Protecting factories from cyber-attacks

Siemens wins takeover bid for Dresser-Rand SIEMENS is set to acquire US-based power equipment manufacturer Dresser-Rand in a US$7.6 billion cash deal.

Dresser-Rand, which has headquarters in Texas, USA, and Paris, France, had an annual turnover of approximately US$3 billion in 2013 and approximately 8,100 employees. The company covers applications such as high-pressure field injection and oil recovery, gas liquefaction, gas transmission and refinery processes, with almost 100,000 rotating equipment units installed in more than 150 countries.

Kongsberg and Ricardo join forces

AMIDST growing concerns over cybersecurity, the EPSRC and the UK National Cyber security programme have announced a £2.5m research programme aimed at helping to protect factories and critical infrastructure from cyber-attacks.

Coordinated by Imperial College’s Research Institute in Trustworthy Industrial Control Systems (RITICS) the three-year program will see teams from a number of UK universities work with industry partners to improve the understanding of the threats posed by cyberattacks and, ultimately, develop solutions that can help repel them.

Explaining the background to the funding, the leader of one of the teams, Lancaster University’s Prof Awais Rashid said: ‘We hear a lot about cyber–attacks, but one of the things we’ve ended up ignoring for a long time is a lot of the industrial control systems used in, for example, power plants, water treatment facilities, and the power grid.’ The research aims to protect critical infrastructure from cyber-attacks Rashid said that whilst many early industrial control systems had little or no connectivity to the outside world, current systems are increasingly interconnected. And

whilst this level of connectivity opens up a host of opportunities (such as enabling engineers to remotely interrogate, monitor and even control systems via their smart phones) the openness of current systems can pose serious threats to their security and resilience.

Whilst innovations like the Shodan search engine –which allows users to locate devices that are connected to the internet – have helped industry understand the need to improve security, Rashid told The Engineer that there is still plenty of work to be done.

‘People don’t realise that they have a lot of vulnerabilities – we’ve done tests, and systems are sometimes really, really open and organisations don’t realise’ Under the latest program, different teams will be looking at different aspects of the problem. Whilst Birmingham University will carry out a security analysis of the National Grid and the UK rail network, researchers from London’s City University will be looking at how risk is communicated to different stakeholders within an organisation.

Elsewhere, a team from Queens University Belfast will investigate vulnerabilities within the national grid as wind or solar generated electricity comes on stream.

RICARDO AND KONGSBERG have signed a framework agreement for the development of the Kongsberg Wind Farm Management System (WFMS), as well as related condition monitoring systems for a range of other industrial sectors.

The Kongsberg WFMS is a turbine independent decision support system and the collaboration between Kongsberg and Ricardo will investigate the potential integration of the new Ricardo SensorLife technology into Kongsberg’s WFMS. Kongsberg selected Ricardo to support the development of the WFMS largely due to the company’s expertise in wind turbine drivetrains, which includes the physical mechanisms of failure of drivetrain bearings, and Ricardo’s extensive research into advanced sensor techniques.

Subsea electricity exchange cables TWO SUBSEA electricity cables will be built linking Norway with the UK and Germany, allowing the three countries to exchange renewable energy to balance electricity supply.

The construction of the two 1,400MW cables has been welcomed by the European Commission.

“This will help enormously to integrate renewable energy in North-West Europe,” said Günther Oettinger, Vice-President of the EU Commission and commissionaire for Energy.

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TRANSPORT ADS GROUP

A UNITED VOICE

ADS Group is the premier trade organisation advancing the UK aerospace, defence, security and space industries.

T

he aim of the ADS Group is to support the UK’s aerospace, defence, security and space sectors.

That’s particularly important because it’s an area where the UK is a world leader and the intention is to maintain that position.

ADS Group was established as

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a trade organisation in 2009 but, since it was formed by a merger of organisations that already represented the different elements, it retains knowledge and expertise from the original organisations. It is, therefore, the voice of authority regarding the needs, challenges and opportunities for industries vital to the UK economy as major

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drivers for growth and prosperity.

Challenges have been particularly acute during the global economic crisis. “We have seen a dynamic response from the industries we represent, with businesses coming together and working with government through the Aerospace Growth Partnership and the Defence Growth Partnership to identify

opportunities and make the most of these opportunities,” recalls Chief Executive Paul Everitt.

“For the defence sector, government spending remains constrained. However, the UK is home to a well-established and world-leading defence sector, which puts it in a good position to make the most of new export opportunities as long as the right investment and

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TRANSPORT ADS GROUP

focus is placed in the development of future technologies.

“ADS continues to work closely with government and has played a prominent role in the Aerospace Growth Partnership and the Defence Growth Partnership — important government and industry initiatives to prioritise opportunities and encourage the right investment to ensure we

retain our world-leading market position for the long-term. We have also been working closely with the Home Office on the establishment of the Security and Resilience Growth Partnership.”

The outcome is the UK aerospace industry is growing ten times faster than the UK overall, employs 109,100 people directly and supports many thousands in

other sectors. The sector has grown 14% annually since 2011, with improved business confidence, investment and a focus on driving growth through exports. Paul says: “The Aerospace Growth Partnership has worked hard to put the right support in place to help UK industry make the most of significant increases in demand for new aircraft. The positive

impact of this work is being felt, with almost three quarters of companies planning to increase investment next year and one in four looking at reshoring activity back to the UK.” ADS has around 900 members in the UK, ranging from small start-ups to large corporations and global operations. They include manufacturers, equipment

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TRANSPORT ADS GROUP suppliers, service companies and operators and, for them, the organisation provides support in many ways. “ADS offers a packed programme of more than 170 events per year in addition to organising UK groups at international exhibitions, offering a valuable opportunity for networking and forging new connections,” outlines Paul. “We facilitate access to the latest tender and business opportunities and provide assistance for SMEs with government funding and business development or building links with prime contractors. ADS has an important role to play in influencing UK and EU governments, representing the interests of industry. Members can participate in more than sixty boards, committees and special interest groups which offer a valuable mechanism to discuss and debate particular issues or challenges faced by businesses.”

The biggest and best known event is the Farnborough International Airshow, organised by wholly-owned subsidiary Farnborough International Limited.

This year’s event attracted more

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“ADS has an important role to play in influencing UK and EU governments” than 100,000 trade visitors and 1,500 exhibitors from 75 countries, affording ADS members the opportunity to showcase the country’s world-leading capabilities to a global audience. A record breaking $201 billion of orders and commitments were made at the show.

Another arm of ADS is the British Aviation Group, the leading representative body for UK companies in the airport and aviation development sector. It has 200 member companies and its primary role is to help UK companies win business in the UK and overseas as well as helping them identify suppliers.

ADS is a member of the Aerospace and Defence Federation that unites alliances

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and provides a single voice for the industries. It manages SC21 (21st Century Supply Chains) that aims to improve supply chains for increased competitiveness of UK industry. Paul says: “Around 650 businesses are on the continuous improvement journey, more than 300 of which have been presented with an award for their work on the programme. To achieve an SC21 award, a company must demonstrate world-class business performance in all aspects, including delivery and services to customers, internal business efficiency and a continuous sustainable improvement culture throughout the organisation.”

Recent years have seen increased collaboration between

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TRANSPORT ADS GROUP

ADS has a packed programme of more than 170 events per year

industry and government to develop strategies, identify new opportunities and make the most of them. Its relationship with key influencers and decision makers enabled ADS, as Paul explains, to significantly influence the content of the Defence Reform Act: “During the legislative process, ADS played an active role in lobbying at each stage of the Bill to ensure key decision-makers were aware of key industry concerns.

ADS engaged constructively with Ministers, MPs and key MOD officials to propose positive and constructive solutions to improve it. As a result, many of these solutions have been adopted.”

Its work on the Defence Reform Act resulted in important changes that ensured intellectual property will be protected and the Single Source Regulatory Office will remain impartial. Additional exemption of contracts from the new regulations will only be

applied in exceptional circumstances, MOD challenges to contract prices will be limited number and SMEs will be protected from excessive burdens.

“Looking towards the end of 2014 and into 2015, our priority will be a continued focus on delivering key objectives, building on our success to ensure we maintain and build our influence over key activities such as industrial strategy, innovation policy and the upcoming Security and Defence Strategic Review,” remarks Paul.

“Our sectors are critical to driving the innovation, exports and well-paid jobs that will secure UK economic growth and we will continue to work to raise awareness of this as well as continuing campaigns and policy initiatives to support our members’ success.”

For more information: www.adsgroup.org.uk Tel: 020 70914500

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TRANSPORT GKN AEROSPACE

MAKING THINGS

FLY

GKN Aerospace designs and manufactures complex, high-performance, high-value integrated metallic and composite assemblies for aerostructures and engine products

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GKN Aerospace, a leader in the manufacture of highly complex composite and metallic aerostructures and engine products, is a first tier supplier to the global aviation industry. With over 100 years aerospace experience, the company, which also focuses its efforts on military and civil markets, harnesses a wealth of knowledge and advanced manufacturing technologies to supply highvalue, integrated assemblies in both metallic and composite materials. In addition, GKN’s expertise extends to glass, acrylic and polycarbonate transparency systems.

Employing approximately 12,000 people in more than 35 facilities across four continents, the global business has witnessed substantial investment to ensure it remains at the forefront of technology delivering real and practical benefits to its customers. Through strategic partnerships with the world’s major airframers and engine OEMs, the company is equipped to

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TRANSPORT GKN AEROSPACE

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TRANSPORT GKN AEROSPACE deliver competitive advantage through advanced design and manufacturing that provides best value and enhanced performance.

This has resulted in GKN consistently retaining its position as a world leader in aerostructures, engine systems, nacelles and transparencies.

Complementing this is GKN’s comprehensive and responsive aftermarket service.

ADDITIVE MANUFACTURING Recent developments include the announcement that GKN is to lead research collaboration into additive manufacturing. This will see the company head-up a consortium of UK companies in a three-and-a-half year, £13.4m research and development programme called Horizon (AM) that builds on GKN’s extensive and fastdeveloping additive manufacturing capability.

The Horizon (AM) team includes GKN Aerospace, Renishaw, Delcam and the Universities of Sheffield and Warwick. The programme is backed by the UK’s Aerospace Technology Institute (ATI).

Horizon (AM) will take a number of promising additive manufacturing (AM) techniques from research and development through to viable production processes, able to create components that could be as much as 50% lighter than their conventional counterparts, with complex geometries that cannot be cost

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“Recent developments include the announcement that GKN is to lead research collaboration into additive manufacturing”

effectively manufactured today. These new processes will unlock innovations in low drag, high-performance wing designs and lighter, even more efficient engine systems – and lead to dramatic reductions in aircraft fuel consumption and emissions.

‘BUY TO FLY’ RATIO The programme will focus initially on using AM techniques to create near net shape parts which require very little machining. This will dramatically improve the ‘buy to fly’ ratio of the part by reducing the considerable cost in time and material wastage associated with the conventional machining of metal forgings. With material wastage as high as 90% for some parts, a sig-

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nificant reduction here will also provide major environmental benefits.

Rich Oldfield, Technical Director, GKN Aerospace explains: “AM incorporates a range of hugely promising manufacturing technologies that the UK aerospace sector must fully understand and exploit if it is to retain its position as the largest national aerospace industry outside the USA. This strong consortium has the expertise and understanding to continue the process of industrialising these technologies for use in both current programme updates and next-generation aircraft.”

Elsewhere, GKN has won a multi-million pound contract for Bombardier Global 7000 and Global 8000 rudder and elevator. The company was selected by Bombardier Aerospace, Belfast

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TRANSPORT GKN AEROSPACE

to design, develop and supply the composite integrated rudder and elevator for the new Global 7000 and Global 8000 ultra long-range business jets. The multi-million pound contract adds to already significant GKN work packages on these aircraft.

These composite structures will be developed and manufactured at the company’s Cowes facility on the Isle of Wight, UK. First deliveries to Bombardier in Belfast will take place in 2014 and will continue through to 2026.

For the Global 7000 and the Global 8000 aircraft, GKN Aerospace is already contracted to: design, develop and produce the transparencies, including the high performance cockpit windows and ultra-large passenger cabin windows; and to design, build and supply the advanced composite winglets and ailerons.

GKN will exploit its extensive expertise in complex composite design and manufacture to provide a lightweight, integrated rudder and elevator structure that meets programme performance and weight requirements.

Neil McManus, CEO, GKN Aerospace – Europe and Special Products states: “Our engineering expertise across composites and transparencies will make a vital contribution to meeting the remarkable range and emissions Continued on page 194

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TRANSPORT GKN AEROSPACE goals of the Global 7000 and Global 8000 aircraft.” He added: “This latest contract win illustrates both our growing relationship with Bombardier Aerospace, which includes the supply of critical structures for the CSeries aircraft’s advanced composite wings, and also our increasing participation in the business aviation market.”

Launched in 2010, the Global 7000 and Global 8000 aircraft will have the ability to reach more destinations non-stop than ever before, delivering unprecedented levels of performance, flexibility and comfort.

COMPOSITE STRUCTURES As a leader in the supply of complex composite structures to the aerospace market, GKN has seen its windows exceed industry performance benchmarks across the board and become the reliable, high performance/low risk product of choice for the full range of aircraft in today’s market – from supersonic military applications to the latest business jets. In addition to these contracts for the Global family of aircraft, the company supplies the aileron and winglet for the Bombardier CSeries aircraft.

Indeed, with an ongoing determination to innovate, GKN has completed a two-year structures technology maturity (STeM) programme to create an advanced winglet using new automated processes. Results show that, were the winglet to enter series production today, these processes could lower manufacturing costs by approximately 20% - producing a cost effective winglet with a lower parts count suitable for new or retrofit installation.

From design through to manufacture the winglet has been a vehicle to trial the latest software tools and modelling, manufacturing and testing methods in areas such as structural design, automated manufacture, assembly

“This latest contract win illustrates our increasing participation in the business aviation market” technologies and analysis tool. A novel design, including a waffle skin construction, has been manufactured and assembled using innovative robotic technologies and new lightweight fixing techniques. The result is a winglet with lower weight, lower parts count, 50% fewer fasteners and 25% less time per fastening.

Rich Oldfield, Technology Director, GKN explains: “We believe many of the processes progressed and proved through this STeM programme will be introduced across the aerospace sector to speed and improve the manu-

facture of a wide range of items such as engine components, nacelles, small wing box structures, vertical and horizontal tail planes, flying controls and undercarriage doors.”

ONE ELEMENT This advanced winglet project is one element in a £12m STeM programme led by GKN Aerospace and including Bombardier, Spirit and GE. STeM’s aim is to support new concepts in wing design that push the boundaries of aerodynamic performance and contribute to securing work in the UK for the next generation of aircraft. It is a collaborative research and development project funded under the UK centre for aerodynamics programme by the UK government’s Technology Strategy Board (TSB) and Department for Business, Innovation and Skills (BIS). The STeM winglet project was undertaken by GKN Aerospace and jointly funded by the company and the TSB. GKN Aerospace leadership of this STeM project follows the completion of a ‘Grand Challenge’ in 2011. There, a consortium of 22 companies from across British industry concluded a one-year challenge set by the TSB, on behalf of BIS. This challenge required the companies to collaborate to progress innovations in vital composite manufacturing technologies.

For more information: www.gkn.com

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TRANSPORT SMMT

THE

DRIVING INDUSTRY Mike Hawes, Chief Executive of The SMMT takes a look at the UK’s thriving and diverse automotive industry

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ou only have to look at the headlines in recent months to know that the automotive industry is in rude health. At the time of writing, the new car market has marked its 29th consecutive month of growth, the forecast for 2014 has been increased to 2.45 million vehicles (an increase of 8% over 2013) and 2015 should be stable at these high levels. In terms of UK production, a new car rolls off a line every 20 seconds, with investment commitments set to deliver a steady increase in output over the next few years. There is also a range of new models – and even a new brand – scheduled to roll off of UK production lines in 2015.

The value of the automotive sector to the wider UK economy is significant. The sector turned over more than £64 billion last year, adding over £12 billion to the UK economy and accounting for 3% of GDP. It exported £34 billion worth of goods to more than 100 countries, while investment into 20

the UK totalled in excess of £2 billion.

This is all the product of a thriving, diverse automotive sector. The UK is home to seven mainstream car manufacturers, eight major premium and sports

MANUFACTURING AND ENGINEERING MAGAZINE

car manufacturers and more than 100 specialist and niche manufacturers. Meanwhile, there are seven manufacturers of commercial vehicles and another nine who produce buses and coaches. Eight of the world’s 11

Formula One teams are based in the UK, as well as 13 R&D centres and six design centres. When one adds in the 2,350 automotive suppliers in the UK the total employed by the sector is over three quarters of a million people.

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TRANSPORT SMMT

“The SMMT has expertise in every area of the industry”

Such a strong and vibrant industry needs an equally dynamic trade association. The Society of Motor Manufacturers and Traders (SMMT) was founded in 1902, by automotive pioneer Frederick Simms. Its purpose has always

been to support and promote the UK automotive industry both at home and abroad, ensuring the Society is active in every aspect of the industry.

SMMT’s membership currently stands at more than 600

automotive companies. These range from mainstream global car manufacturers and key automotive suppliers to low-volume vehicle manufacturers, supply chain SMEs and aftermarket component providers. Such a varied pool of members demands a varied approach to tackling the industry’s ever-changing requirements.

The SMMT has expertise in every area of the industry. Its dedicated policy team prides itself in building and cultivating strong relationships with the country’s key influencers, ensuring SMMT’s members are considered in all decisions affecting the industry.

Similarly, SMMT’s technical experts have their finger on the pulse of global vehicle legislation.

Their hard work and deep knowledge ensures that when new legislation is introduced, the specific needs of the UK industry have been taken into account.

Specialists in the automotive supply chain, aftermarket, bus and coach and commercial vehicle sectors ensure that all our members are well serviced.

Meanwhile, our business improvement experts work to ensure that doing business in the

UK is as beneficial as possible.

Services such as the Automotive Supplier Finder online tool and Meet the Buyer event help match automotive buyers with suppliers.

SMMT’s Funding and Support guide highlights different ways in which businesses can obtain funding, while the bi-annual Open Forum events allow supply chain companies a unique networking opportunity.

SMMT’s dedicated vehicle data team have many decades of automotive data at their disposal, allowing members to understand their market perfectly.

To help drive investment into the UK industry, SMMT’s International specialists work closely with the Automotive Investment Organisation (AIO) and UK Trade and Investment (UKTI). It holds a UK Pavilion at every major global automotive trade show, helping its members to get in front of overseas audiences.

The UK automotive industry is thriving and SMMT is working to ensure this positivity will continue for years to come.

For more information: www.smmt.co.uk

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MANUFACTURING AND ENGINEERING JENKS AND CATTELL ENGINEERING LTD

THE

COMPLETE SOLUTION Jenks and Cattell Engineering has a wealth of manufacturing expertise, consistently producing high quality general metal presswork, welded assemblies and laser fabrications.

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Jenks and Cattell Engineering Ltd, which was established in 1886, provides an impressive range of engineering services including metal presswork, laser fabrication and welded assemblies for manufacturing purposes, with extras including riveting, painting/plating, bending and nut insertion.

The company is one of the longest established metal presswork, fabrication and assembly companies in the UK. As part of the Newship Group, a private family owned group of companies, Jenks and Cattell Engineering benefits from its Europe-wide scope which sees the Group enjoy sales in excess of ÂŁ140m per annum through the operation of engineering, packaging, construction and hire markets across the continent.

Customers enjoy a number of benefits working with Jenks and Cattell Engineering.

This includes cost-competitive components, a comprehensive range of manufacturing,

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MANUFACTURING AND ENGINEERING JENKS AND CATTELL ENGINEERING LTD

“Located in the West Midlands, Jenks and Cattell Engineering is currently more competitive than ever in terms of cost, quality and lead times” services and equipment, as well as high quality products, excellent customer service and a continuous improvement philosophy.

COMPLETE SERVICE The company offers a complete service for all presswork and assembly requirements and has the expertise, capability and capacity to manufacture any shape, size and volume of components. An extensive range of manufacturing services including manual welding, robotic welding, progression, transfer, single operation presses and laser blank, can be welded, assembled and surface finished to meet customer requirements.

The company also enjoys the capability and capacity to manufacture prototypes, low volume and high volume runs, and will follow a customer’s components’ product life cycle from cradle to grave.

Jenks and Cattell Engineering has delivered billions of cost competitive components to

customers worldwide, many of them leaders in their industry sector including automotive, white goods, heating manufacturers, off highway and lighting manufacturers.

MORE COMPETITIVE Located in the West Midlands, the company is currently more competitive than ever in terms of cost, quality and lead times, and with a new addition to the factory floor in the form of a new Trumpf TruLaser 3030 laser machine, the engineering business now has the capability to increase production efficiency rates and more than double its laser capacity.

The new laser machine will accompany an existing laser machine which cuts steel up to 16mm, and the new TruLaser will have the ability to cut 20mm of mild steel, 15mm of stainless steel and 10mm of aluminium.

The 4kw laser will have a compact lift master attached which will enable Jenks and Cattell Engineering to offer customers an increased

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production rate as the automation will enable the machine to run through the night.

With both laser machines, Jenks and Cattell can offer customers services including: laser etching, imprinting part numbers, bar codes, logos or any other markings on the component.

The machines are highly accurate due to the automation; there is an improved edge quality for both simple and complex components.

The laser machine is ideal for prototypes and small to high volume of products at the most cost efficient rate as there is no tooling expenditure. The laser was fitted in the first week of October, allowing Jenks and Cattell to provide

“Jenks and Cattell Engineering has dedicated itself to offering a second-to-none service that helps its customers reduce their costs” excellent lead times using a “just in time” delivery system with the ability to provide laser based orders within 72 hours where applicable.

Indeed, Jenks and Cattell Engineering has dedicated itself to offering a second-to-none service that helps its customers reduce their costs. To this end it has developed a successful seven-year relationship with a Chinese company in order to reduce costs for the customer.

Its current set-up involves its Tooling and Project Engineer visiting the Shenzhen factory every six weeks to project manage the process and ensure that quality is being maintained and that the components are up to standard. Using Chinese tool makers have allowed Jenks and Cattell Engineering to reduce customers tooling costs by 45%-50%, and since 2007, it has

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MANUFACTURING AND ENGINEERING JENKS AND CATTELL ENGINEERING LTD sourced over 500 parts from its partner in Shenzhen. With customers taking advantage of the lower production rates, the company is able to save them between 28%-35% piece price, with a guaranteed pay back within seven months.

Having built up an excellent relationship and communication system with its suppliers, it guarantees to keep customers updated on the progress of their tool during manufacture.

Indeed, not only does Jenks and Cattell Engineering provide cost reductions to customers, it is able to deliver sample parts within six-weeks, using UK material, and produce a full delivery within 16 weeks.

Jenks and Cattell Engineering does have a tool-shop on site at its Wolverhampton Engineering factory, which enables its specialist toolmakers to adapt and maintain tools throughout the tools working life, which increases quality and product life-cycle for customers.

EUROPE It comes as no surprise that Jenks and Cattell Engineering has vast plans to grow within Europe. Recently the company visited the Innotrans exhibition in Germany as part of its exporting growth project. The sheet metal engineering and manufacturing capabilities of presswork, laser fabrication, bending and both manu-

“It comes as no surprise that Jenks and Cattell Engineering has vast plans to grow within Europe”

al and robotic welding give the company a very competitive advantage to serve various industries throughout Europe.

With a key focus on quality including an inhouse Macro-Weld facility, ISIR and CMM as well as ISO 14001, ISO 9001 and TS 16949 accreditations, Jenks and Cattell Engineering has the ability to manufacture goods for a wide range of industries, including rail, automotive, off-highway, heating, electrical, white-goods, agricultural and energy at a very high standard.

The company’s enduring standards are also seen in its environmental performance. For another year running it has achieved the ISO 14001:2004 Environmental Management System Certification.

It received one of its annual onsite SGS audits recently which closely analysed and

reported on areas including maintenance, management programmes, communications, document control, operational control, legal compliances, hazardous waste, emissions, noise, packaging, measurement, transport and disposal of oil, to which, no aspects alerted any problems The company is proud to have successfully maintained its certification for the ISO 14001:2004 since 1998 and it will continue working to the current excellent standard throughout all of the environmental and managerial aspects to improve its productivity towards metal pressings, laser fabrication and welded assembly manufacturing.

For more information: Tel: 01902 303 223 www.jcel.co.uk

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ENERGY AND ENVIRONMENT BOWYER ENGINEERING LIMITED

PRECISION ENGINEERING EXCELLENCE Knowledge and expertise in precision engineering has been passed through Bowyer Engineering for over 65 years.

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Bowyer Engineering Limited was founded on 23rd April 1946 when Paget Bowyer, the grandfather of current MD, James Bowyer, started an engineering company in Clerkenwell then known as Cathanode Limited. Paget Bowyer was a Chartered Electrical Engineer and the Company initially worked in the provision of tooling and equipment for the telecommunications industry.

In 1955 the Company changed its name to Bowyer, Smith and Partners Limited – at this time the aims of the Company were to carry out precision engineering and tooling and to manufacture and sell electrical goods – however, the precision engineering activities soon outgrew other aspects of the business.

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ENERGY AND ENVIRONMENT BOWYER ENGINEERING LIMITED In 1969 Michael Bowyer (Paget’s son) joined the Company (by now re-named Bowyer Engineering Limited) – Michael had previously worked for Smiths Industries in polymer engineering applications – and shortly afterwards the Company re-located to a new greenfield site in Andover as part of a London “overspill” agreement. Seven years ago James Bowyer joined the Company (the third generation of the Bowyer family to work in the Company) and is now Managing Director, whilst Michael Bowyer remains the major shareholder and continues to work on the design and manufacture of special purpose machines.

The Company continued to evolve by establishing good working relationships with other companies which had also moved to Andover and, in addition to the core business of batchwork machining, developed and constructed automated special purpose machines for use in diverse high-tech industries. An opportunity arose to design and build robotic welding fixtures, one of the early customers being ESAB who had relocated to Andover at about the same time.

Another one of the early customers, and with whom the Company continues to enjoy an excellent working relationship of over 50 years, was Rolls-Royce aero engines for which the Company initially supplied mercury slip ring units and inhibiting rigs – Rolls-Royce remain one of the Company’s largest customers.

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Much of the work now carried out is the sub-contract Research and Development of special processes for automation of single crystal wax casting and composite pinning processes. Assisting in the automation process are SCS Controls who provide the electrical and control functions Bowyer’s unique solution processes.

The Company is unable to elaborate due to strict confidentiality agreements, but the work is in support of the new Rolls-Royce ABCF facility recently opened in Rotherham.

Other long-standing blue-chip aerospace customers for who it continues to provide support include IAE, Hydro and Qinetiq.

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ENERGY AND ENVIRONMENT BOWYER ENGINEERING LIMITED

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MB Engineering

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ENERGY AND ENVIRONMENT BOWYER ENGINEERING LIMITED Following-on from the success of the early special purpose machines, and taking advantage of opportunities when they arose, the Company diversified into Instrumentation in the 1980’s and subsequently expanded into NDT support early in the 21st century.

The Company continue to operate in the batchwork machining field and have recently undertaken a major review of machining processes allowing a greater flexibility and throughput from the dedicated 12,000 sq ft machining facility. Productivity has increased by such an amount that there is now an extra 3040% capacity that can be filled with new work (a sales drive to fill this unexpected capacity is now under way). Furthermore, the introduction of ITC tooling has cut tooling costs by 50% each month in the machining of a diverse range of materials that include super duplex, stainless steel, nimonics, Inconel, aluminium and mild steel. A new 5-axis machine is also due to come on stream in early 2015 which will allow the company to become even more competitive.

ADDITIONAL TRAINING All Bowyer Engineering employees are positively encouraged to undertake additional training relevant to their specific tasks, in particular with regard to CAD and CAM

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“Health and Safety has a high importance within the Company” operations. The Company works closely with Andover Skills Training Fund and has been fortunate to have received grant aid to assist with some of the training costs.

The Company have a reputation as solution providers for part or complete projects and have the ability to evolve into new areas as and when required. A good example of this is the recent provision of EDM notching facilities for the NDT industry.

The Company has undergone a structured expansion since the 1970’s, but the recent economic downturn had a significant impact on batchwork machining generally and robotic fixture output in support of the automotive industry.

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ENERGY AND ENVIRONMENT BOWYER ENGINEERING LIMITED

Fortunately, the Company’s operations across other sectors with longer phased products meant that staff were able to be re-allocated to areas which were not so badly affected.

Health and Safety has a high importance within the Company, and staff are encouraged to attend relevant courses. A senior member of staff is tasked with maintaining and monitoring H & S performance.

Engineering is an energy intensive activity and the opportunities to reduce the Company’s carbon footprint is thus limited. The Company has a policy of recycling materials wherever possible and is currently in the process of fitting reducedenergy lighting units over the factory floor.

Use of 3D CAD modelling has allowed Special Purpose Machines and fixturing design to be right first time. The introduction of new machining methodologies and tooling products was a step made easy by the support and combined input from the shop floor staff and management. Working closely with ITC has also made vast improvement to Bowyer Engineering’s ability to machine competitively.

The Company looks forward to maintaining their current strong performance and eagerly anticipates the introduction of new machines to increase output and competitiveness.

For more information: Tel: 01264 365 921 bowyerengineering.co.uk

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MANUFACTURING AND ENGINEERING DENHOLM REES & O’DONNELL LTD

INCREASING EFFICIENCY

Denholms offer a precision engineering manufacturing service

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Precision engineering is the name of the game at manufacturing service provider Denholm Rees & O’Donnell Ltd. The company provides this service for the production of anything from a single component through to complete assemblies and can offer a genuine one-stopshop for a customer’s requirements.

The company’s reputation remains strong thanks to securing experience and clients in a variety of sectors. This includes oil & gas, petrochemicals & plastics, motor manufacturing (OEM), aerospace, marine and food processing.

Thanks to state of the art CNC machining services through to comprehensive fabrication and assembly facilities, Denholm works to fully certified quality and process management systems to ensure customers receive the components and products they need on budget and to the agreed delivery schedule.

Recently, the company has developed its operations to ensure maximum efficiency and value for money. The management team within the group recognised that increasingly customers were looking for ways to improve efficiency and cost-effectiveness in the supply process and avoid the time and administrative costs involved in going backwards and forwards between different suppliers to attain each finished component.

While turning to larger “one-stop” suppliers to take care of everything was an obvious answer, it meant losing all the benefits of working with smaller, specialist companies, where their personalised approach and the wealth of dedicated experience and skill delivered real benefit.

Denholm Rees & O’Donnell together with sister company C E Edwards set out to create a

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best practice solution by forging partnerships with other OEM suppliers to offer customers all their dedicated knowledge and service through a narrower, more integrated supply chain. They have been able to draw on their existing relationships and extensive understanding of the technical and manufacturing elements of the process to bring together suppliers and customers to everyone’s benefit.

The concept was devised as a way of delivering the best of both worlds for all concerned, streamlining the process to cut out unnecessary costs and delays without losing the highly focused knowledge and skills, as well as the flexibility and individualised service, offered by smaller specialist companies. It now encompasses a focus on partnerships all the way

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MANUFACTURING AND ENGINEERING DENHOLM REES & O’DONNELL LTD

“Recently, the company has developed its operations to ensure maximum efficiency and value for money”

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along the supply chain to give a series of strong, seamless links for the best possible results.

Managers at the two sister companies are delighted with the positive response to the initiative, with smaller OEMs retaining contracts and clients enjoying the advantages of working with them with none of the potential downsides.

It is an evolving model in which all parties are engaged to deliver best quality and best value.

The business also took an alternative approach through its partnering with other OEM suppliers in order to offer a narrower supply chain which still taps into the key skills of dedicated sub-contract engineering specialists.

For example, a major European pump manufacturer was looking to reduce its supply chain by sourcing cast components fully machined and finished complete from a single supplier.

Historically these components had been sourced by the OEM as castings from a dedicated foundry and then shipped to machining specialists for processing and final supply back to the OEM as finished machined items with each supplier providing their key skills, knowledge and experience to the production process.

CALL 01484 437300

For more information www.denholms.co.uk Tel: 0151 525 1663

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ENERGY AND ENVIRONMENT BCECA

PROMOTING THE INDUSTRY

BCECA is the trade association representing the principal companies in the UK that provide engineering, procurement, construction and project management services to the process industries.

A

lthough BCECA only has 22 members, up from four when it started in 1966, they are mostly multi-nationals involved in anything from embryonic technology studies to the execution of some of the largest and most complex offshore installations and onshore sites in the world. BCECA companies are world leaders in project

management, engineering and construction, with world class skills, execution capability and experience across a broad spectrum of industries. They directly employ over 25,000 professional staff in the UK, with revenues of over £11 billion and a supply chain of around £50 billion.

COMPLEX PROJECTS The work of BCECA is therefore critical to an industry that is involved in some of the most

“We aim to ensure the UK engineering contracting industry is recognised by government, universities, institutions, other engineering sectors and the public” TRACEY SHELLEY DIRECTOR

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technically advanced and complex projects around the world.

Members of the association cover the design, procurement, supply and erection of major chemical, oil, gas or petrochemical process plants. BCECA aims to promote the status of the industry, encourage co-operation between various involved organisations and provide a means of joint consultation and action to promote and protect the interests of members.

Much of BCECA’s work is undertaken through ten technical committees that enable member companies to share experiences

and information and to develop and implement solutions that have included training standards, programmes and qualifications for the sector in conjunction with the ECITB. The association’s members have faced many challenges over the years, a recent one being skills shortages within the industry.

BCECA is trying to address this through its Industry Days within universities and by promoting Design and Draughting and Project Control apprenticeships with employers. “BCECA recognised the need to focus on the skills shortage, the promotion

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ENERGY AND ENVIRONMENT BCECA

BCECA MEMBERS 2014 Air Products plc Aker Engineering & Technologies Limited AMEC Group Limited Bechtel Limited CB&I UK Limited Costain Oil, Gas and Process Limited ENI Engineering E&P Limited Fluor Limited Foster Wheeler Energy Limited JM Davy Technologies Limited of the sector and recruitment of young people into the industry,” recalls Director Tracey Shelley.

“When they were looking for a successor to the previous Director, who was retiring, I was brought in as much of my career has focused on engineering skills development.”

She is, in fact, the first female Director and the first not to come from within the industry.

PREVENTING RESTRICTIONS A major benefit to members is the availability of indices to track pay movements within the industry.

BCECA also recently tackled, as Tracey recounts, problems over

immigration legislation and visa restrictions that were hampering the industry: “BCECA, through its HR Managers Committee, engaged the services of an immigration lawyer to help the government understand the restrictions which were being placed on it through changes in immigration legislation and visa restrictions. These often prevented overseas client representatives from engaging with project teams in the UK.” Ongoing services provide a focal point for representation of members’ interests to government and other interested parties. The association also updates employers

on relevant developments and enables information sharing and networking. Looking ahead, as Tracey emphasises, the key ambitions remain unchanged: “We aim to ensure the UK engineering contracting industry is recognised by government, universities, institutions, other engineering sectors and the public. We will also promote the sector and encourage young people to enter the industry via apprenticeships or after graduation.”

For more information bceca.org.uk Tel: 020 7839 6514

Jacobs Engineering UK Limited Jacobs Engineering UK Limited McDermott Marine Construction Limited Petrofac Engineering Limited SNC Lavalin UK Limited Simon-Carves Engineering Limited Technip E&C Limited UOP Limited URS E&C UK Limited WG Mustang Engineering Whessoe Oil and Gas Limited WorleyParsons Europe Limited

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ENERGY AND ENVIRONMENT FOSTER WHEELER

INNOVATIVE

ENERGY SOLUTIONS Foster Wheeler has a reputation for delivering high quality, reliable, technically advanced energy and industrial infrastructure and facilities

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Foster Wheeler is a leading global engineering, procurement and construction (EPC) contractor and power equipment supplier with a reputation for safe, on-time, onbudget delivery of high quality, reliable, technically advanced energy and industrial infrastructure and facilities.

Foster Wheeler was formed in 1927 from a merger of two companies based in the United States: the Power Specialty Company and the Wheeler Condenser & Engineering Company, whose roots go back to 1891. In its early years, the company’s main business was the design and manufacture of boilers and related equipment. Over the years, the company grew internationally through acquisitions, and it entered the engineering and construction business in the 1920s.

The company, which has its executive offices in the UK, significantly strengthened its financial position as a result of a restructuring program during 2002-2004 and re-listed on the Nasdaq Stock Exchange in 2005.

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ENERGY AND ENVIRONMENT FOSTER WHEELER

Foster Wheeler offers a complete range of skills and services from the earliest ‘ideas’ stage of planned investments, through concept selection, front-end engineering design, project management, EPC and into commissioning and ongoing asset support. Foster Wheeler has permanent offices in 30 countries and over 13,000 skilled personnel.

The company, which works with clients to develop and deliver solutions in the upstream oil and gas, LNG/midstream, refining, chemicals and petrochemicals, power, minerals and metals, environmental, pharmaceuticals and biotechnology sectors, has proven expertise in managing large, complex projects. It also benefits from a global reach and longstanding international presence, strong relationships with clients and cutting-edge processes and technologies which have combined to position it as a leader in the field.

In addition, Foster Wheeler boasts a very strong commitment to health and safety and is extremely proud of its safety achievements. For example, it has won more than a hundred safety awards for its outstanding international safety

Foster Wheeler boasts a very strong commitment to health and safety and is extremely proud of its safety achievements.

performance from governments, industry bodies and clients over the years.

In June 2014, the company was also honoured with its seventh successive Order of Distinction Award for Health and Safety by UK’s RoSPA. The Order of Distinction is RoSPA’s highest achievement award and is only presented to those companies which have attained at least 15 consecutive RoSPA Gold Awards for outstanding health and safety performance. Foster Wheeler has received 21 consecutive RoSPA Gold Awards.

“Industry forums, such as BCECA, provide a key focal point, critical mass, and drive to allow

the contracting industry as a whole to shape its own future, something that individual companies would struggle to achieve,” said Filippo Abbà, Chairman & Chief Executive Officer, Foster Wheeler Energy Limited. “When you combine this with networking, information exchange, and the opportunity the various BCECA forums also provide for individual development, it is easy to see why such groups are strongly supported by the industry as a whole, and by Foster Wheeler in particular.”

For more information: Tel: 0118 913 1234 www.fwc.com

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ENERGY AND ENVIRONMENT FLUOR LIMITED

THE

MEETING CHALLENGE

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Fluor Limited has been operating for more than 55 years in the UK, combining global strength with local focus for customers in the United Kingdom, Europe, Middle East, Africa and around the world.

With its operations passing 55 years in service, Flour continues to enjoy its position as one of the world’s leading publicly traded engineering, procurement, construction, maintenance and project management companies. Its endeavours are global but its focus is local with customers enjoying attentive solutions to their needs in the UK, Europe, the Middle East, Africa and elsewhere around the world.

The business was first established in the UK as Fluor Engineering & Construction Co. Limited in 1957 and has grown to become one of the largest engineering companies in the country.

The first project was Texaco’s Trinoil Plant, Point-A-Pierre Refinery in Trinidad. Significant milestone projects included Greenfield and retrofit projects in the energy and chemicals markets in the United Kingdom, Europe, and the emerging markets of the Middle East.

Importantly, Fluor has committed itself to be a forward-thinking, innovative leader in the emerging alternative energy markets. An example of this is its work on the Greater Gabbard wind farm project off the Suffolk coast, which is the world’s largest offshore wind farm, providing renewable energy to more than 415,000 homes.

Indeed, sustainability is the basis for much of Fluor’s long-term ambitions. The concept of sustainable solutions means meeting the needs

of its clients while conducting business in a socially, economically, and environmentally responsible manner to the benefit of future generations. The company’s practices create fundamental value for Fluor and all of its stakeholders, clients and their customers, employees, investors, suppliers, contractors, and the communities in which they operate.

Clients rely on Fluor to help address sustainability challenges and issues, including the need to improve energy efficiency, reduce greenhouse gas emissions, and design and build more environmentally friendly, less costly manufacturing facilities.

Fluor clients expect ethical conduct; high levels of employee knowledge and expertise;

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ENERGY AND ENVIRONMENT FLUOR LIMITED excellence in health, safety, and environmental matters; and a proactive approach to community involvement. Fluor’s 2013 Sustainability Report “Beyond the Blueprint – Growing Sustainably” describes how it is working to realise the possibilities of global economic growth and development, while managing issues that could impact its stakeholders.

Going hand-in-hand with sustainability is health and safety. Fluor has, understandably, advanced its processes and procedures to improve safety across all its endeavours. Back in 1994, Fluor made a bold commitment to safety excellence and established a new industry standard for safety around the world. Nearly two decades later, Fluor continues to be committed to providing a safe working environment for employees and subcontractors. Fluor’s ZERO IncidentsSM Program is a benchmark for safety in the provision of engineering, construction and maintenance services. The ZERO Incidents Program reinforces Fluor’s commitment to safety as the company’s foremost value, incorporates Fluor’s commitment to health and environmental protection and provides the highest level of challenge, achievement and recognition for Fluor projects executed around the world.

This level of service quality, enduring standards and attention to detail has led to Flour

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“Back in 1994, Fluor made a bold commitment to safety excellence and established a new industry standard for safety around the world”

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working on prestigious projects around the world. It currently has a 10-year contract to service the needs of the national roads telecommunications network in the UK. This public-private partnership (PPP) provides program management, design, construction, financing, and maintenance of the integrated communications systems that link the roadway communication devices (emergency telephones, CCTV, etc.) along the motorways and other main "A" roads in England with the national traffic control and police control centres.

During the first phase of the contract, the two-year New Build Phase, the Fluor-led GeneSYS Telecommunications Limited consortium replaced aging telecommunications

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ENERGY AND ENVIRONMENT FLUOR LIMITED network technology with new transmission equipment (state-of-the art Multi-Protocol Label Switching (MPLS) technology) along 3,000 km of motorways. The consortium also developed a 24/7 Network Operations Centre (NOC) with a new suite of Operational Support System software to monitor the network.

In subsequent phases, GeneSYS will operate and maintain the network for eight years and then hand back the system to the Highways Agency, providing support services for an additional two years.

Elsewhere, over a six-year period beginning in 1996, Fluor helped DuPont U.K. upgrade and modernise several of its nylon intermediates plants located at the Wilton Complex in Teesside, England. The focus was on upgrading the plants in a cost-effective manner.

WORK-SHARING PROGRAM Coordinating its activities at three offices in the United Kingdom, Spain, and the United States, Fluor implemented a successful work-sharing program that resulted in sizable cost-savings and no lost-time incidents or accidents. Fluor also brought expertise gained from years of working on DuPont facilities to the Wilton project.

The plants were built originally by ICI, a British company. Revamping the plants as DuPont-owned and operated facilities required a number of steps. These included overall process and product evaluations, technology transfers from DuPont USA, and safety and environmentally focused upgrades.

After the updates went live, Fluor followed up with operations and maintenance training.

As part of this program, called the DuPont Wilton 2000 Program, Fluor U.S.A., Fluor U.K., and Fluor Spain combined to perform detailed engineering and procurement operations, among other operations.

The results were a very effective execution of the project. Zero accidents or negative incidents of any sort in six years of work both at Teesside and at the participating Fluor offices in the

DEDICATED TO BUILDING STRONG COMMUNITIES FLUOR is dedicated to building strong communities and having a positive impact on the communities in which we work and live, through Fluor’s projects, philanthropy and employee volunteering. Fluor focuses on community development through education, employee volunteerism and environmental stewardship.

During 2012 Fluor Cares activities in Farnborough included: 41,746 volunteer hours spent in fundraising, community and education related initiatives 41,006 participants took part in fundraising, community and education related initiatives 4£32,832 raised (£15,034 for the Prostate Project ‘charity of the year’; £17,798 for other charities)

Various Fluor Limited charitable contributions support key activities to promote education and community enhancement. Community initiatives during 2013 include: 4The Source – Fluor Farnborough’s 2013 Charity of the Year 4Science, Technology, Engineering and Mathematics (STEM) Education 4Interschool Engineering Competitions 4Westfields Junior Technology Awards 4Farnborough Sixth Form College Mentoring and Student Sponsorship 4University of Surrey Grant 4Comic Relief 4Loughborough University Material Engineering Department Sponsorship

United Kingdom, the United States, and Spain resulted in a high level of client satisfaction.

The project was successfully concluded in 2001. Three major projects were implemented at the DuPont plants in Teesside with Fluor support. Cost reductions were sought and achieved during the course of the project and Fluor played a major role in helping develop the new Catalytic Oxidation Process for the N20 abatement at the nylon intermediates plants. Significantly, this program won DuPont’s Excellence Award.

For more information: www.fluor.com Tel: 01252 291000

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ENERGY AND ENVIRONMENT KBR

KBR works alongside clients worldwide to deliver any project, any time, any place

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KBR has built a worldwide reputation for its specialist technologydriven engineering, procurement and construction services, and operates in the US, Americas, Africa, Asia-Pacific, Australia, Europe and the Middle East.

From its headquarters in the “energy capital of the world� Houston, Texas, KBR delivers a wide range of services through the following business units: Oil & Gas; Downstream; Technology; Infrastructure, Government and Power (IGP) Americas; IGP Europe, Middle East and Africa; IGP Asia Pacific; IGP North American Government and Logistics; Canada Operations; U.S. Construction; Building Group; Industrial Services; and Ventures.

Proud of its reputation and a leader in the field, KBR has developed strong relationships with clients in the government and infrastructure sectors by offering low-cost, high-efficiency and reliable solutions. The company is also an industry leader in transforming hydrocarbon

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ENERGY AND ENVIRONMENT KBR resources into value across all sectors of the energy and chemicals industries. By designing and constructing energy and petrochemical projects that offer the latest and best process and design technologies, it has established a solid position as a partner to oil and gas operators in meeting the ever-increasing demand for energy.

In Europe, KBR has a large presence with thousands of employees working on projects across the continent. The company works closely with the U.S. State Department and the United Kingdom’s Ministry of Defence on a number of projects, and its engineering and consulting teams are busy throughout the region. KBR's subsidiary Granherne, has been historically active in Europe and in the North Sea. Some of its major projects include the South Hook LNG terminal, which stores natural gas

imported from Qatar and two natural gas processing plants at Karsto, Norway. KBR provides substantial front end engineering and design as well as engineering, procurement and construction services for offshore platforms.

KBR employs 2,500 staff in the UK. It has been operating here since 1933 and provides high-level expertise to both government and private-sector clients in a range of industries. In addition, Granherne, a front-end engineering consultancy and subsidiary of KBR, also has a presence in the UK. KBR’s focus in the UK is on defence, policing and home affairs, as well as energy, and has become respected as a world leader in the provision of programme and project management, engineering, procurement and construction, logistics, services and training.

KBR has been operating in the UK since 1933 and provides high-level expertise to both government and private-sector clients

Its UK business designs and delivers solutions to the most complex challenges facing the public and private sectors. From making British soldiers’ lives better by providing them with the modern accommodation they deserve, to managing the world’s largest energy programmes, and supporting Britain’s biggest police force as it transforms its vast estate; KBR creates, transforms and sustains assets and organisations.

Recently, KBR along with Rheinmetall Defence submitted a joint venture bid to acquire the Defence Support Group, a Ministry of Defence Trading Fund that provides military vehicle maintenance and repair services to the United Kingdom Armed Forces.

This is a unique partnership, with the right combination of logistics, business management experience and technical expertise in defence land systems to transform and develop the DSG. Under KBR Rheinmetall ownership DSG will become a centre of excellence for defence engineering and remain a trusted partner, implementing the British Army's strategy for equipment support.

For more information: www.kbr.com Tel: 01372 865000

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ENERGY AND ENVIRONMENT ACHILLES

POWER IN

NUMBERS

Achilles creates and manages a global network of collaborative industry communities, allowing trading partners to share high quality, structured, real-time data.

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chilles plays a vital role in allowing its trading partners to share high quality, structured, real-time data.

Through the creation and management of a global network of collaborative industry communities, Achilles acts as an independent partner, providing validated data and insightful analytics to enable buyers across a variety of sectors identify and manage risk while suppliers can

increase market reach and compliance in addition to minimising costs across the network as a whole.

The success of Achilles over the years is represented by its membership with around 800 of the world’s leading buying organisations and 90,000 key suppliers currently benefiting from the Achilles’ network of over 40 different communities in 11 industry sectors. Consistent development also sees the services expanding into new markets regularly.

This network of communities is supported by over 950 dedicated employees, providing local support in 29 different languages, based in 23 different countries. Indeed, if the proof is in the pudding, Achilles enduring achievements and valuable customer support can be seen in its work with some of the world’s best-known companies. These include Shell, Balfour Beatty, Toyota Motor Europe, E.ON, EDF, Vale, ABB, Santos, Petrobas, Chevron, Maersk, Skanska, Statoil, Vattenfall, Repsol YPF, Alstom,

Iberdrola, Acciona, Abertis, National Grid, BHP Billiton, Yamana Gold, Halliburton, Anglo American, Aston Martin, Jaguar Landrover Petrobras and Exxon Mobil.

Achilles works through the “power of a network of communities.” This structure allows buyers with access to a broader range of verified, compliant suppliers while suppliers themselves gain access to a broader range of potential buyers.

The required verification and data gathering processes are

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ENERGY AND ENVIRONMENT ACHILLES standardised within the community and are facilitated by Achilles’ local support teams based around the world.

The result is a significant reduction in the work required by both suppliers and buyers to manage and reduce risk within their community and a substantially lower cost of compliance for the community as a whole.

Achilles’ communities range in scope from large individual enterprises seeking to improve compliance and risk management across their multi-national base of subsidiaries to broad, industry-wide communities of over 100 major buyers and 10,000 suppliers.

SHARING BEST PRACTICE The global network produces additional benefits by sharing best practice in compliance and risk management between industry sectors and across geographies and allows buyers and suppliers to open up trading opportunities in new markets.

Services are comprehensive and tailored. Achilles provides its

“Working together, Achilles and the utilities industry have seen significant increases in business critical areas”

communities with a SaaS-based buyer and supplier compliance, risk and performance management platform alongside expertise in the specific industry sector and in procurement compliance and risk management issues in general.

Support is also given to assist suppliers in compiling the relevant information and achieving compliance. In addition, resources to continuously update, verify and, if required, audit the information are available.

The business first began in 1990 when it was founded in

Norway with the goal of helping organisations identify, assess, qualify, and monitor suppliers throughout the supply chain.

Achilles’ first success came with the launch of a supplier pre-qualification service for Norway's oil and gas industry.

The principal driver was to reduce operating costs. It was established “by the industry for the industry” against a background of low oil prices.

The concept was that ifyou can collect and provide information once only and share it with all, it avoids the significant duplication of effort and the associated resource time consumed in doing that.

From this simple business model, which is applicable to any industry or geography, Achilles has rapidly expanded into 23 countries across all continents.

Indeed, the company now operates in multiple industries and sectors, from automotive to utilities with a group turnover of around £70m.

GREATER VISIBILITY

ACHILLES HAS 22 GLOBAL OPERATIONS ARGENTINA / AUSTRALIA / BRAZIL / CHILE / COLOMBIA / DENMARK / GERMANY / HONG KONG / INDIA / IRELAND / ITALY / NETHERLANDS / NIGERIA / NORWAY / PERU / PORTUGAL / SLOVAKIA / SPAIN / SWEDEN / UK / UNITED ARAB EMIRATES / USA

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As supply chains become more globalised, buyers and suppliers need greater visibility of supply chain risks. The Achilles solution today is not just about reducing operating cost. It therefore offers a broad range of procurement risk management tools and services including on-site supplier audits, carbon footprint data, sustainability and CSR information, multi-tier supply

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ENERGY AND ENVIRONMENT ACHILLES

ACHILLES SECTORS AUTOMOTIVE TRANSPORT ICT CONSTRUCTION UTILITIES PHARMACEUTICAL OIL & GAS FMCG MINING & CEMENT POWER & TECH PUBLIC SECTOR SERVICE INDUSTRIES

chain mapping and procurement legislation advice.

Recent achievements include the cementing of its reputation as the world’s leading provider of supplier pre-qualification, audit and compliance services for the utilities industry, with the renewal of the contract to independently manage these functions for all the main companies in the UK.

UVDB Achilles has operated the Utilities supplier pre-qualification system UVDB in the UK for the last 20 years, working on behalf of the principal Utilities buying organisations to independently risk-assess more than 10,000 suppliers, carry out comprehensive audits and help businesses comply with EU regulations. UVDB is now the biggest buyer and supplier community in Europe.

After a full market review comprising representatives from over 40 companies including EDF

Energy, Northern Powergrid, Scottish Power, SSE, Wales and West Utilities, Western Power Distribution and UK Power Networks, agreed that Achilles’ solution performed best in terms of effectiveness, global reach and value for money. Achilles will now continue to run the service for a further minimum period of five years.

Adrian Chamberlain, Chief Executive of Achilles, said: “It is a real honour that after a full market appraisal, the UK’s biggest utilities companies have extended their 20year working relationship with Achilles.

“Working together, Achilles and the utilities industry have seen significant increases in business critical areas, such as health and safety, compliance, corporate social responsibility and we are proud this has been recognised.

“However, we are by no means complacent and part of the continuous improvement of the service, we have pledged a series

of additional innovations to further enhance user experience for buyers and suppliers. We look forward to working with the community to implement these improvements over the coming months.”

In total, Achilles now manages 19 pre-qualification communities for the utilities industry across the world, working on behalf of 189 buying organisations to manage the pre-qualification activities of more than 39,000 suppliers.

Across all the communities, Achilles provides a managed service including a technology platform to collect information

from suppliers, validate the data, and publish information to buying organisations in a way that is compliant with procurement rules in each country. Users can also access additional services such as on-site safety, health and environmental audits, advisory services and site-specific information and an advertising platform for “call for competition” notices, and award announcements.

For more information: Tel: 01235 820813 www.achilles.com

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ENERGY AND ENVIRONMENT EIC

ENERGISING YOUR BUSINESS The EIC provides one of the most comprehensive sources of energy projects and business intelligence in the energy sector today.

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erving as the leading Trade Association for organisations who provide goods and services to the global energy market, The EIC is dedicated to helping its members understand, identify and pursue business opportunities through comprehensive business intelligence and news relating to sector developments. Through providing services which open up new avenues for its members, The EIC aims to both support and promote sustainable growth throughout the global supply chain whilst bringing member companies together.

As a not-for-profit organisation, The EIC is dedicated to fully supporting each of its members wherever possible.

Employing over a million

individuals, The EIC membership generates over £100 billion in revenue throughout the UK and is open to registered companies who supply goods and services to the energy sector. With an incredible following and member-base, this has placed The EIC as a core component at the centre of the energy sector.

Through the provision of intricate and detailed market intelligence through EICDataStream, The EIC’ s online energy project database, The EIC is able to keep all of its members abreast of the changes and developments in the market, promoting pre-emptive adaptation and enabling them to keep ahead of the competition. The EICDataStream, which serves as a global online energy database tracking, planning, regulatory and contracting activities across 9,850

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projects worldwide, enables its member companies to access information, reports and networking with key procurement personnel.

With its network of UK and regional offices throughout key energy markets around the globe, The EIC affords its members a platform from which to expand their global business base and connect with other sector companies. Through the delivery

of acquired business intelligence and market knowledge, these branches are able to fully support The EIC’ s members globally and promote networking with other organisations such as suppliers, buyers, support services and others operating within the sector.

In keeping its members up to date on market trends and developments, The EIC offers great support for its members

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ENERGY AND ENVIRONMENT EIC

through its information services.

The company explains how they achieve this, saying: “The EIC publishes a series of informative online news, e-bulletins and in-depth magazines to keep members connected with the world of energy. From up-to-theminute news and regional market insights, to expert comment and relevant features, the EIC delivers powerful knowledge direct, while providing members with a media

platform to market themselves.“ Further supporting its member-base with training solutions, EIC Training assists in the provision of training courses, workshops and industry overviews to ensure that all members are both kept informed and have the necessary skills to keep up with the ever-changing energy industry. Through the provision of both hand-on practical experience and learning

alongside theoretical knowledge, EIC Training offers a fully comprehensive training portfolio which has received much acclaim and is testament to the company’s dedication to supporting the sector as a whole.

Through running a variety of events programmes for its members, The EIC allows for many organisations within the sector to connect suppliers with industryleading organisations and develop

sustainable relationships. These events, while uniquely important in their own right each offer the opportunity for decision makers at organisations on every level of supply chain to share information and connect for the good of the sector and their individual endeavours.

For more information: www.the-eic.com Tel: 020 7091 8600

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LOOKING BACK AT...

...ADA LOVELACE the first computer programmer

We take a look at some of the pioneers, inventors and inventions in that have helped shape the manufacturing and engineering industies

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da Lovelace was an anomaly; a woman who was able to successfully contribute to technological advancement in a predominantly maledominated Victorian England.

Indeed, through her work with mathematician and inventor Charles Babbage, Lovelace provided key research which helped create what was called the “Analytical Engine”. This mechanical general-purpose machine is an early example of what would become the modern day computer. So in effect, Lovelace was one of the world’s first computer programmers.

As one of Lord Byron’s children, Lovelace came from wealthy, privileged stock. Born in London, she initially disappointed her father who expected a “glorious boy” but her achievements would certainly have inspired pride in the renowned poet if he had lived long enough to see them.

Ada Lovelace Day is an international celebration of the achievements of women in science, technology, engineering and maths (STEM).

This year, it falls on Tuesday 14 October 2014 and the Royal Institute is celebrating it with a host of female scientists, engineers and celebrities.

For more information about this event visit: www.rigb.org

Throughout her life, Lovelace had an almost obsessive interest in scientific developments and, notably, human brain activity. Her work to create a mathematical model detailing how the brain gives rise to thoughts and nerves to feelings was, in part, driven by a preoccupation inherited from her mother about potential “madness”. In her short life – she lived only until the age of 36 – she also carried out significant work within the fields of phrenology (the study of the human skull) and hypnotism.

Although the extent to which her contribution to Babbage’s work varies to some degree between commentators, Lovelace’s work did emphasise the difference between the Analytical Machine and previous calculating 52

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machines. Her notes make reference to its ability to be programmed to solve problems of any complexity. She realised it could be used for a number of operations not simply number crunching.

Writers Betty Toole and Benjamin Woolley, as well as programmer John Graham-Cumming, who developed a contemporary project to construct the first complete Analytical Engine, all claim Lovelace’s research provides significant insight. Indeed, her notes were a conceptual leap from previous ideas about the capabilities of computing devices. These ideas foreshadowed the capabilities and implications of the modern computer.

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ADS GROUP A UNITED VOICE

PLUS:

We take a look at Foster Wheeler which has built a reputation for delivering high quality, reliable, technically advanced energy and industrial infrastructure and facilities.

ISSUE 410

GKN AEROSPACE We take a look at GKN Aerospace manufacturer and designer of complex, high-performance integrated metallic and composite assemblies for aerostructures and engine products

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BOWYER ENGINEERING Knowledge and expertise in precision engineering has been passed through Bowyer Engineering for over 65 years.

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ALSO INSIDE...

4Fluor 4KBR Infrastructure 4BCECA 4SMMT 4Achilles ...Plus much more