Manufacturing & Engineering Magazine Issue 418 by Manufacturing and Engineering Magazine

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ISSUE 418

MANUFACTURING AND ENGINEERING MAGAZINE

M M MANUFACTURING AND ENGINEERING MAGAZINE

INSTITUTE OF EXPLOSIVE ENGINEERS promoting the occupational competency, education and professional standing of those who work with explosives

RED RHINO CRUSHERS Performance, reliability and value for money P60

SHARING IN GROWTH

ISSUE 418

Developing highly valued manufacturing for this generation and the next... P42

PLUS Next Generation Data UK

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Comment editor’s

ISSUE 418

www.memuk.org

y m o n o c E K U t s o 6 Steps To Bo

Through Manufacturing

How can the manufacturing sector aid the UK’s economic growth and long term prosperity? After the challenges of the recession it is essentially a standing start for many in the industry but at least that “start” began a couple of years ago meaning we’re now, hopefully, up and running. Recently I was impressed by ideas put forward by The Institution of Engineering and Technology (IET). It highlighted six key steps that the manufacturing sector needed to take to fulfil its potential and consequently boost the UK economy. These steps took the form of pressuring government to focus on areas including innovation, support for SMEs and energy efficiency in order to meet growth projections. Margaret Wood, a member of the IET’s Manufacturing Policy Panel, said: “If given the right policy support, UK manufacturing is well placed to deliver growth in globalised markets that will benefit the UK economy.” It is therefore vital that the government works with industry leaders and businesses big and small to develop the platform for sustained recovery. Wood added: “We need a long-term vision with consistent policies to help manufacturing companies increase their productivity and grow. By focusing on these six steps, we can ensure that manufacturing continues to create jobs and expand our economy, helping to make the UK globally competitive.” More needs to be done, she said, in innovation. The UK has an excellent science and research base but far too often the output is not exploited in the country. Here, more help needs to be made available, specifically for small to medium sized enterprises, in order to create investment opportunities, support full development cycles and scale-up ideas for commercial success and job creation. This will be complemented by SME support (nearly 90% of innovation is done through SMEs) while building stronger relationships with procurers will help manufacturers - particularly SMEs - understand the opportunities available in public procurement. The skills shortage was highlighted as a concern and an area that needs quickly addressing but through measures such as the sector adapting to fast-moving new technologies, particularly in regards to the internet, and becoming more energy efficient, challenges for the industry will become very attainable ambitions.

Daniel Stephens Group Editor

Magazine Manager Daniel Beardsley Feature Managers Tom Waite Elliott Jenkinson Kyle Joyce Bradley Drake Group Editor Daniel Stephens Editor Ciaran Jarosz Contributors Jeff Senior Amy Marsden Alice Rose Batley Art Editor Stacey Brewer Designers Carla Taylor Sam Dickinson Production Vicki Lindsay Lisa Pollinger Accounts Nick Charalambous Manufacturing and Engineering Magazine is published by: Trafalgar Publishing Ltd, 1st Floor Turnbridge Mills, Quay Street, Huddersfield West Yorkshire HD1 6QT Tel: 01484 437314

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 418

www.memuk.org

SECTIONS

8 MANUFACTURING AND ENGINEERING 38 RAIL 42 FOOD & DRINK 44 CIVIL ENGINEERING 64 ACADEMIA

34 INSTITUTE OF EXPLOSIVE ENGINEERS

ASSOCIATIONS 8 SHARING IN GROWTH

Offering a helping hand to the global aerospace and manufacturing industries

22 TECHUK

Defining the world for today and tomorrow

48 STEEL CONSTRUCTION CERTIFICATION SCHEME The SCCS was established in the early 1980s to provide a Quality Management Systems certification service for steelwork contracting organisations

54 CONSTRUCTION EQUIPMENT ASSOCIATION Equipped to matter

8 OWTH SHARING IN GR 2

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REGULARS 4 UPDATE

The latest news from the industry.

68 THE LAST WORD Underwater robotics

FEATURES 12 STONE FOUNDRIES Leading European manufacturer of high intensity aluminium and magnesium castings

24 NEXT GENERATION DATA UK

16 CW FLETCHER

Leaders in precision engineering

24 NEXT GENERATION DATA UK For the changing world

30 PRISM ELECTRONICS Focussed on your needs

34 INSTITUTE OF EXPLOSIVE ENGINEERS Promoting the occupational competency, education and professional standing of those who work with explosives

36 SPEX

Energetic innovation

38 ROMAG

16 CW FLETCHER

38 ROMAG

A bright future for bespoke glass

40 RAILTEX 2015 2015 show a huge success

42 BRITANNIA KITCHEN VENTILATION A basic system to a complete solution

46 ICARUS LIGHT STEEL FRAMING Setting the trend in the design, manufacture and installation of light steel framing

50 JCC ENGINEERING Leading from the front

52 LIONWELD KENNEDY 100 years of service

60 RED RHINO CRUSHERS Worldwide presence in the crushing sector

60 RED RHINO CRUSHERS

64 INNOVATION IN EDUCATION A look at the manufacturing and engineering innovation coming out of the UKâ&#x20AC;&#x2122;s top colleges and universities

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update Southampton establishes rail link with China The University of Southampton has signed an agreement with Chinese high-speed train manufacturer CSR Qingdao Sifang (CSR Sifang) to establish a new centre for railway research and development. The ‘China-UK Rail Transit Technology Joint Research and Development Centre’, which also involves Imperial College London and the University of Birmingham, will undertake research to develop new technologies, materials and manufacturing processes for high-speed trains and metros. The University of Southampton’s Institute of Sound and Vibration Research (ISVR) is collaborating with CSR, which has manufactured around half of China’s entire high-speed rail fleet, on research and development into biodynamics and ride comfort, vibration and noise reduction, human factors and staff training.

Audi celebrates RS birthday with new model Back in 1994 a bunch of Audi and Porsche engineers got together to create the RS 2 Avant, a brawny estate – based on the Audi 80 – intended to reinstate the Ingolstadt company as a performance car manufacturer after the successes it had enjoyed with the quattro the previous decade. RS, now an established sub-brand operated by Audi’s Quattro GmbH division, is 21 years old this year, and is vastly changed from the fledgling operation that started with the RS 2. The RS 3 Sportback, based on the compact fivedoor A3, is the latest of the line. Like all RS models, it looks relatively meek and mild but, with a 367hp I5, 2.5 litre turbo engine, seven speed double clutch gearbox and all wheel drive, it can outperform many a supercar and with the drive select system in its dynamic setting, the noises it makes are capable of making an entire 4

village think that war has just broken out. In the intervening years all RS models have been numbered according to the car on which they were based: so, the RS 4 is a derivative of the A4, and so on. And whereas there used to be only one RS model in the Audi range at any given time, usually arriving at the end of the donor car’s life cycle to add a bit of lustre just before run out, now there are as many as the market will take, appearing as and when they are needed. Audi’s attitude today is that if the customer wants them, then they can have them. RS models regularly account for up to 5% of sales of the corresponding range. RS stands for RennSport, which translated literally means racing sport, and the cars which wear the red, black and silver badge are the pinnacle of the Audi fleet, except for the standalone R8.

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Only 16 of these halo variants have ever been produced, based on the A3, A4, A5, A6, A7, TT and Q3. The most popular for RS conversion has been the A6, saloon and Avant, with four models between 2002 and 2013. Next up comes the A4, with three itinerations between 2000 and 2012. Last year Audi produced its first RS SUV based on the Q3. It took Audi six years to introduce its second RS model after the RS 2 when the RS 4 Avant came out in 2000. These days they pop up at regular intervals: in 2013 alone there were three – the RS 5 Cabriolet, RS 6 Avant and RS 7 Sportback. The RS 2 churned out a meaty in its day 315hp but that now seems pale in comparison with some of the power outputs of subsequent models. The most powerful RS of all time was the V10-engined bi-turbo RS 6 of 2008, which delivered 580hp.

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update ROLLS-ROYCE AND LIEBHERR-AEROSPACE TO DEVELOP MANUFACTURING CAPABILITY FOR ULTRAFAN ENGINE

MANUFACTURING JOB APPLICATIONS SURGE The UK’s independent job board, CV-Library, has announced the manufacturing sector saw the strongest growth in job applications last month. Compared to May 2014, job applications saw an overall rise of 36.5 per cent, resulting in higher volumes of skilled candidates applying for each job. Despite a drop in jobs between April and May 2015, jobs in the industry have still seen a year-onyear rise of 24 per cent. Whilst May 2014 saw an average of 26.2 job applications per role, the figure has increase to 31.3 in May 2015, a rise of 19.75 per

Rolls-Royce and Liebherr-Aerospace are to establish an equal joint venture to develop manufacturing capability and capacity for the power gearbox of Rolls-Royce's new UltraFan engine. Rolls-Royce say the geared UltraFan is based on technology that could be ready for service from 2025, offering a minimum 25 per cent improvement in fuel burn compared with first generation Trent engines. The company further claims that the power gearbox will enable the UltraFan to deliver efficient power over a range of take-off thrusts for high-bypass ratio engines of the future. For the highest thrust engines, each single gearbox will be capable of handling the equivalent horsepower produced by more than 500 family cars. Located in Friedrichshafen, Germany, the joint venture will provide production engineering for

the power gear drive train components. The manufacturing of the components will initially be done in existing Liebherr facilities. As production volumes increase, the joint venture will look at options for creating a standalone manufacturing infrastructure. Rolls-Royce will continue to lead the design definition and design integration of the power gearbox, as well as the testing activities. In a statement, Tony Wood, RollsRoyce president, aerospace said: "The UltraFan engine design includes a suite of new technologies to power nextgeneration aircraft. The power gearbox is an integral part of this new design, and we are delighted to be partnering with Liebherr on this highly efficient future power gearbox technology." The establishment of the joint venture is subject to the usual legal approvals.

cent, which is greater than any other sector last month. These figures are way ahead of the current average ‘application to job ratio’ of 16.6:1, which actually dropped nationally by 2.6 per cent. Lee Biggins, Founder and MD of CV-Library, explains: “The growth in the number of candidates applying for jobs in manufacturing sector is excellent news for businesses in the industry. “This rise means organisations have a broader spectrum of skilled professionals to choose from, meaning they can be much more selective when filling roles.”

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update 3D PRINTER AIMS TO CHALLENGE INJECTION MOULDING ON HIGH VOLUME PRODUCTION A 3D printing machine capable of rapidly producing anything from aerospace components to running shoes as cheaply as traditional manufacturing techniques is being developed in Yorkshire. The machine, being built at Sheffield University, will be able to produce plastic parts three times larger and 100 times faster than existing comparable 3D printing, or additive manufacturing (AM) machines. Unlike existing AM techniques, in which a laser is used to fuse the powder, high speed sintering uses an infrared-absorbing ink Crucially, it is also the first AM device capable of producing parts as cheaply as conventional injection moulding techniques, according to its developer Prof Neil Hopkinson in the Faculty of Engineering at Sheffield University. The technology is based on a process known as high speed sintering (HSS), developed by Hopkinson while at Loughborough University, in which a polymer powder is selectively fused together layer by layer, to produce a specific shape. But unlike existing AM techniques, in which a laser is used to fuse the powder, HSS uses an infra-red-absorbing ink. This ink is printed onto

the powder bed in the desired pattern, and an infra-red lamp is shone onto the powder, said Hopkinson. “The energy from the lamp is absorbed by the ink, which gets hot, melting the particles that are lying underneath,” he said. Meanwhile the rest of the powder, which has not been printed on with the ink, remains cooler, he said. The machine will be capable of producing parts of up to one cubic metre, or approximately the size of a washing machine. The researchers estimate that small components could be produced at a rate of less than one second per part. The machine, which is being developed with funding from the Engineering and Physical Sciences Research Council, will be built at Sheffield’s Advanced Manufacturing Research Centre. It will then be transferred to the university’s Centre for Advanced Additive Manufacturing for further research. Meanwhile, the technology is being licensed to machine manufacturers by Loughborough University, and the researchers expect to see the first systems on the market within the next few years.

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CONFIDENCE DROPS AMONG MANUFACTURERS Manufacturers have reported the biggest decline in optimism for two years, with exporters impacted in particular, according to new research by BDO. The firm's latest Business Trends Report revealed that a slow performance in the eurozone and a strong British pound have hit exporting manufacturers, along with low oil and gas prices, curbing investment in the sector. As a result, BDO's Manufacturing Optimism Index dropped by four points to 103.4. BDO said the results could be down to the size of the sector, which is still smaller than it was prior to the economic crash of 2008. Andrea Bishop, audit partner and head

of BDO in South Wales and South West England, said: "The government’s plans to rebalance the economy are vital, but it is equally vital that the manufacturing sector reaps the benefits from these plans and receives the help it needs to thrive. "In particular, we need to see the regional powerhouse plans translate into real support for the manufacturing sector." Lawton also said measures such as reducing national insurance for recruiting manufacturers could create more than 1,839 jobs in Wales alone. "Manufacturing is a key sector for economic growth, so specific support could help boost the economy as a whole," he said.

FUGRO AWARDED ALASKA LNG GEOPHYSICAL SCOPE Fugro has been awarded a geotechnical and geophysical (G&G) programme by ExxonMobil Alaska LNG (AKLNG), for the Alaska LNG Project. This programme follows the successful completion of a similar, smaller programme carried out in 2014. The geotechnical scope of work includes drilling and sampling of borings for the onshore liquefaction facilities, marine terminal and offshore pipelines. It also includes installation of monitoring wells, seismograph and measurement of soil properties. The geological and earthquake

engineering scope will include assessment of geohazards, source characterisation, probabilistic seismic hazard and site response analyses. Bathymetric, side scan sonar, reflection and refraction surveys and sub-bottom profiling will also be conducted to assist in developing an integrated site model. These studies will assist AKLNG and its contractors to proceed with the front-end engineering and design (FEED) of the LNG terminal and associated offshore pipelines. AKLNG is a consortium comprising ExxonMobil, ConocoPhillips, BP TransCanada and the State of Alaska.

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update

UK AUTOMOTIVE SECTOR LAUNCHES NEW SEARCH TOOL The UK automotive sector, led by the Society of Motor Manufacturers and Traders (SMMT) and Motor Codes, has launched a new consumer-facing web portal to enable motorists to identify if their vehicle is on a safety recall list. Customers will also be directed to their nearest dealer so that any necessary remedial work can be carried out as quickly as possible. The Vehicle Safety Recall search tool, which operates using the Vehicle Identification Number (VIN), is a one-stopshop for car owners and buyers of used cars and vans to check if the vehicle is subject to an outstanding safety recall that they, or a previous owner, may have missed. The new service is available online via Motor Codes (motorcodes.co.uk), the automotive industry’s governmentapproved regulatory body, and is funded and managed by the Society of Motor Manufacturers and Traders (SMMT). The UK’s vehicle recall process, administered by the Driver and Vehicle

Standards Agency (DVSA), is already stringent and highly successful. The number of vehicles repaired following a recall campaign in the UK consistently exceeds 90% – one of the most successful compliance records anywhere in the world, and some two and a half times higher than the average rate for all consumer goods in the UK. The number of recall campaigns in the UK has fallen by more than a quarter since 2010, further demonstrating the industry’s strong track record on safety performance. There are 36 million cars and light commercial vehicles on British roads, and manufacturers are committed to ensuring they remain safe throughout their lifecycles, through safety tests as well as by closely monitoring any customer incidents. Mike Hawes, SMMT chief executive, said, ‘The UK vehicle recall process is one of the most robust in the world, and manufacturers are constantly striving to make it even better. Essential recalls can be missed when a vehicle transfers between owners so this portal provides a fast way of

checking any safety issues. Vehicle manufacturers are committed to delivering the highest standards of safety and record keeping, to ensure the UK’s excellent vehicle safety record is maintained.’ Mark Terry, managing director at Motor Codes, said, ‘Motor Codes is the automotive industry watchdog and consumer champion, so we are well placed to deliver this service. We are committed to helping UK motorists identify if their car has an outstanding vehicle safety recall issue and to enabling manufacturers to meet their obligations in rectifying these issues’. Car owners and buyers can check the safety recall status of almost any given car or van at motorcodes.co.uk/vehicle-recall by simply keying in the vehicle’s VIN – the 17character number found in the car’s log book (V5C) and in the vehicle itself.3 The service also provides guidance on what to do in the event of an outstanding recall and allows users to link directly to their local dealer to arrange any necessary repair work.

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MANUFACTURING & ENGINEERING SHARING IN GROWTH

A HELPING HAND

Sharing In Growth was set up in 2012 to evolve, improve and develop the UK’s position in the global aerospace and manufacturing markets

The fact the UK is second in the global aerospace market after the US may surprise many people. But the UK government is keen to maintain that position in a fast growing market, which led to the formation of Sharing In Growth in 2012. The organisation was formed through a £50 million Regional Growth Fund grant which, with a recent conditional grant for a further £30 million and in kind contributions from the benefiting companies, amounts to a £250 million programme aiming to secure 10,000 jobs over its life and help drive competitive performance. That requires much work around lean principles, manufacturing

process capability, sub-tier supply chain management, financial and cost modelling and leadership. The way it will do this, according to CEO Andy Page, is quite unique and very ambitious: “To retain that position in the world requires companies to evolve, improve, develop and step up to the challenges the global market faces. With the money, expertise and time at our disposal, we’re doing something on a scale the UK government hasn’t attempted before. We’re trying to create something that is commensurate with the challenges companies are facing so it’s been designed to have a scale and an impact. “We believe high value manufacturing has a place in developed countries like

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the UK and want to develop it for this generation and the next. We want to make it more recognised and highly valued, with the secondary benefits of drawing people through education, providing them with challenging and stimulating jobs, with long-term security and a route for innovation and technology.” Sharing In Growth is headed by experienced management with backgrounds in aerospace and manufacturing, backed by a ninety-strong team that’s set to grow to 120. They work closely with partners that provide business and strategic planning support, inspection and advanced manufacturing research capabilities, and tailored training that is very specific to the circumstances, chal-

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lenges and ambitions of programme members. Those members currently number 33 and have to fulfil certain criteria to be accepted. “They must be high value, UK manufacturing companies that contribute to aerospace, wish to export, have probably gone through the first generation of growth and are looking to build on that and move to mid-cap size,” recounts Andy. “Typically, companies are over £8-10 million turnover but not above £100 million, don’t need to be SMEs and their ownership structure can be anything. But they have to be ambitious, curious, open and willing to learn, change and develop.” Each company receives £1 million worth of funded training and development over a fouryear programme that starts with a period of due diligence around the nature of the company and includes talking to its customers in order to determine what it needs to do. “We then go through a very deep, whole business diagnostic, which takes three to four months,” explains Andy. “It looks at their maturity levels across all key elements of their business covering their board structure, leadership, governance, purchasing principles, manufacturing principles, cost modelling, pricing, production and all the important things in the industry. We come out of that process with an improvement plan that happens over the next two years. Then there is a further eighteen months of sustaining this activity where we check and review to make sure we’ve left them with the knowledge to continue on their own. Overall, each company goes through a four-year programme.”

Each company receives £1 million worth of funded training and development over a four-year programme Sharing In Growth’s role is to co-ordinate, advise and provide the necessary support through the process, ensuring it’s adding value to businesses that will make their own decisions. The longer term hope is that participating companies, which can increase to 64 with the current funding, will perform, compete and form a powerful community offering support for each other. And that, as Andy outlines, is already being encouraged: “We’ve held two better practice sharing forums so far where we have all the companies together. Typically, we choose three or four of those companies to give a presentation on the activities they’re undertaking, the challenges they’ve faced and the things they’ve learnt. They share their experiences with everybody else and they’re remarkably frank and very open, even though some of them are in competition. They recognise there’s a much greater benefit there by everybody learning from each other.” Although the programme’s still at a relatively early stage, with the front runners just going through their first anniversary and most start-

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The immediate aims are to progress the initial 33 companies through the rest of the programme and to recruit additional members

ing improvement activity after completing the diagnostic phase, there are already positive outcomes. Increased confidence has allowed them to be more aggressive in the market and compete more effectively, and that’s contributed to the first £100 million of contract value being secured. The immediate aims are to progress the initial 33 companies through the rest of the programme and to recruit additional members up to the current 64 capacity. After that, Andy believes there’s further potential: “The first priority is to try and do more of this until we maximise the benefit in the UK for aerospace. Then there are potential spin-off benefits because this is going to have a very meaningful impact on a number of companies by making them drive and accelerate their competitive performance. For them truly to grow, they need to

be thinking about technology development and almost certainly need to have access to capital for growth. “We can link up with other schemes that are trying to stimulate technology and access to capital so we can start leveraging the benefits for those companies. There are also many other high value manufacturing sectors, should the government wish to try and expand this model there. The combined effect of having time and the resources to do something means we’ve designed this very specifically to be commensurate with the challenges in aerospace in order to achieve the objective of globally competitive performance.”

www.sig-uk.org Telephone: 01332 269096

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The process for making sand castings has been around for many centuries although the procedure has evolved using techniques such as self-setting sands and resin tooling, keeping pace with the ever-increasing demands of the markets served. Serving markets such as aerospace and defence, these developments have been essential in delivering cost competitive and safe products in a very competitive worldwide market. Stone Foundries has been at the forefront of these developments, indeed class leading in many

pre and post-cast disciplines. Stone Foundries roots date back to 1831 with production of aircraft castings commencing in the 1920s. The company was in the forefront of development of magnesium alloys for aerospace and defence applications and has been involved in some challenging and intriguing projects in its long history. It is now a partner in the Stone Engineering Group, which specialises in casting and machining high quality aluminium and magnesium components for a wide range of engineered products. “We get involved with our customers at

the early design stage where possible and work with them to make sure what they’re designing is manufacturable from a casting perspective and, as importantly, considering commercial, total cost and timescale constraints,” recounts Sales and Marketing Director Bob Bruce. “The products are all bespoke, technically demanding and relatively low volume. For example, typical products supplied are used in most Rolls-Royce civil and military engines, supporting both engine build and spares requirements”.

PRECISION ENGINEERING Stone Foundries is a leading European manufacturer of high integrity aluminium and magnesium castings

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MANUFACTURING & ENGINEERING STONE FOUNDRIES There’s also a collaboration with Cast Technologies Institute, part of the Advanced Manufacturing Research Centre, on processes such as 3D sand printing. Stone Foundries is working on a number of projects, developing the process to potentially flight acceptable standard. This process is not only good for development programmes but potentially covers a gap in the market for the supply of low volume heritage parts and, as Bob recounts, various other innovations: “We use X-ray as an inspection process to make sure our products conform to the specifications. However, the film can potentially erode over time and is expensive to store. “So we now offer a digital X-ray solution whereby the image is stored on a tape, is quicker, cleaner and more environmentally friendly. Stone Foundries was the first light alloy foundry to have this process accepted by RollsRoyce. Also, traditionally post-cast processing includes a full or part dimensional inspection process to ensure conformance to the drawing. We’ve now developed a process where we use a laser scanner to ensure the parts conform, which is far more efficient in time and cost.” Environmentally, foundries have traditionally had an undesirable reputation. The company is mindful of the effects they have on both local and global communities and so has signed up to a unique, DEFRA-funded, action-based research programme. Along with other companies in the Rolls-Royce supply chain, it has access to a resource efficiency manager who will help determine the potential for business improvement while allowing the company to sets its own priorities. The project is expected to last 12-15 months and the outcome will be a more efficient operation with improved environmental credibility through reduced waste of natural resources that include energy, water and materials. The biggest driver of change currently, is

Stone Foundries’ participation in the Sharing in Growth programme. It was the fourth company to be accepted, has just completed its first anniversary and was one of only four companies to be invited to present at the organisation’s Best Practice event. Although only 25% through the four-year programme, the company has seen remarkable improvements. Delivery performance has improved dramatically with the demanding On Time in Full (OTIF) measure increasing from 40% to 90% by the end of the first year and arrears decreasing from £500,000 to £30,000 over the same period. A major benefit from the Sharing in Growth programme has been a significant improvement

“A major benefit from the Sharing in Growth programme has been a significant improvement in employee engagement” in employee engagement. “We ran a survey in February 2014, which found that employees were not really engaged in the business, had a typical distrust of management and, on a scale of one to five, we averaged 1-1.5,” recalls Bob. “During, the year, we ran company briefs explaining the journey, a number of workshops, lean manufacturing exercises, NVQ pro-

grammes and engaging employees in problem solving activities. Sharing in Growth ran the survey again in December 2015. The first survey had a response rate of 67 out of 105 while 85 responded to the second survey with an average score of 4.5 out of 5. This was a remarkable change in such a short period and clear evidence that employees have bought into and see a value in the programme. The knock-on benefits are sometimes unquantifiable but, as evidenced in daily briefs and by regularly walking on the shop floor and talking to people, there is an infectious desire to be part of the team and not purely an employee. That turnaround has enabled Stone Foundries to be more flexible and adaptable, illustrated by a recent request by a customer, Agusta Westland, to increase production of demanding part for its Lynx helicopter programme from 12-13 annually to 53 in 2014. Using some of the tools and techniques developed through Sharing in Growth, and engaging the employees in the challenge, it achieved the target, a feat the customer described as “nothing short of a miracle”. Longer term, Bob believes, the programme is preparing the company for future challenges, saying: “We have to remain match fit so we’re in a position to continue to compete in a very tough international market. It’s enabling Stone Foundries to look beyond its main UK market. We are now seeing further opportunities abroad and are experiencing growth opportunities with customers in France, Italy, Germany and, North America. Interestingly, these customers are aware of Sharing in Growth. I recently received a call from a potential customer in Canada who is quite intrigued about the benefits it’s brought to customers and they’re inviting us to go out there and present our business to them.”

www.stonefoundries.com Telephone: 020 88534648

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MANUFACTURING & ENGINEERING CW FLETCHER

Increasing turnover from £21m to £32m within four years is a tough task for CW Fletcher. Nevertheless, it’s well on the way to hitting the target and that’s partly though its involvement in the Sharing In Growth programme. The company started over 100 years ago, began producing aircraft parts during the Second World War and now has most of its customers in the aerospace and defence sectors with some projects in nuclear and space exploration industries. It remains a private company and the main activity is manufacturing engineering components up to two meters in diameter from different metals and metal alloys, generally high value and in variable volumes. But there’s also involvement in project management and managing supply chains to provide exactly what each customer wants.

“It’s very much dependent on customer needs," states Business Development Manager Richard Phillips. “A lot of the projects we work on tend to be quite long timescales and it’s very rare customers just want a particular component made. Usually there’s a lot of work as well and a supply chain that comes with it. Building key supply chain partnerships enables us to offer our customers the best and most reliable service possible.” The operation is changing to some degree as the company endeavours to make the transition from an SME to something larger, and it’s doing this with the help of Sharing In Growth where it’s been involved for eighteen months. The first six months, as Richard recalls, covered evaluation: “There’s a critical

look a t everything in the business and it highlights a lot of areas where perhaps we thought we were pretty good. There are many areas for improvement, which is one of the core parts of the Sharing In Growth programme. They see a lot of other companies and can point out how others do things or offer alternative methods. You get access to a

PRECISION ENGINEERING Leaders in the field, CW Fletcher’s expert, in-house capabilities mean world renowned quality and innovation for clients

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MANUFACTURING & ENGINEERING CW FLETCHER

network of knowledge that companies of our size can’t normally get hold of. This expertise has been and will continue to be invaluable to our growth plans. “To join the programme, companies must have a genuine desire to change and be able

“It’s building relationships with new technology companies in areas such as metal injection moulding and direct metal deposition”

Fletcher’s core competencies — machining from solid components, fabricated machined assemblies and actuator rings. That requires a complete reorganisation of the manufacturing facility. Any future investments are to be geared towards supporting these value streams and to support the whole process from finding new business, selling to the customer, new product introduction through to full manufacturing and finally to the post-production phase. Richard says: “The future for CW Fletcher is very clear. We have to focus on our three core value streams and ensure all our efforts are geared towards improving these and making CW Fletcher the best and safest place for a customer to place their projects.” As part of Sharing In Growth, CW Fletcher has created a technology road map to ensure

to look critically at their own business. The programme can’t provide solutions unless companies are willing to admit there are already shortfalls in their current business model. The key element is having a willingness to commit and to get people involved throughout the company, otherwise it won’t work.” One outcome of the Sharing In Growth programme is a reorganisation and refocus from a functional manufacturing base to three value streams that are viewed as CW

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it has the right technologies in place for the value stream work on which it’s currently focusing. It’s building relationships with new technology companies in areas such as metal injection moulding and direct metal deposition so it can be involved in the future of where manufacturing is moving. Such relationships are a crucial element of Sharing In Growth, a key principle being to look at supply chains, how the company interacts with them and long-term agree-

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MANUFACTURING & ENGINEERING CW FLETCHER

“Involvement with the Sharing In Growth programme is already starting to pay dividends, with operational savings of £1m already made and £32m of new and retained orders being secured over the next five years” ments. That’s something CW Fletcher has practised for some time, its strategy being to build partnerships with suppliers that are then used as required on appropriate contracts. “We have long standing and reliable supply chain partnerships with several companies such as Fine Tubes, which has been one of our most successful for one of our biggest core products, the actuator rings,” explains Richard. “We’re hoping to maintain that relationship for the future because they are incredibly reliable, working with us in all aspects of their supply. The core products they supply are our steel and titanium tubes and their reliability and willingness to work with us is crucial to our success. “Most of our customers require lower cost manufacturing solutions so we’re currently partnering with a Romanian company and seeing opportunities in India, ensuring CW Fletcher can continue to offer a value for money solution to our customer base. 20

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MANUFACTURING & ENGINEERING CW FLETCHER Other key supply partners include Component Coating and Repair Services, NDT Limited and Wallwork Heat Treatment that allow us to offer a total customer solution. They help us build supply chains for the future of both us and our customers, doing things we can’t do but they do them well so we work closely with them.” Involvement with the Sharing In Growth programme is already starting to pay dividends, with operational savings of £1m already made and £32m of new and retained orders being secured over the next five years. That’s resulted partly from the training provided as part of the programme and encouraging employees to think differently. The new orders include contracts and long-term agreements in Europe, Japan and the USA, partly achieved by proactively promoting CW Fletcher to some of the bigger OEMs in aerospace or industrial power generation. It’s part of a conscious decision to diversify into a much broader range of industries and customers, having been heavily dependent on one major customer not many years ago. New areas include civil power, industrial gas turbine work and renewable energies, undertaking various manufacturing and engineering projects. Richard says: “Sharing In Growth has helped us lay the foundations for our future growth and also made us look critically

at what we are currently, where we want to be in the future and how we get there. There was a realisation quite early on that we couldn’t continue to grow this business without these foundations being in place and without the expertise and knowledge that Sharing In Growth would bring. We’d reached a point of growth that was really as far as we could go without the new modern thinking.” The whole programme fits in with Fletcher’s values and beliefs that are based on trust, openness and honesty. “We’re looking to clearly articulate our vision so we can align our entire business to it,” outlines Richard. “This includes working on core values and a total business culture. We recognise that, without the alignment of the entire company behind the vision and mission statement, our efforts to change our business won’t be as successful until we get all that right.”

www.cwfletcher.co.uk Telephone: 0114 2942200

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tech uk.qxp_feature 2 04/06/2015 16:51 Page 22

MANUFACTURING & ENGINEERING TECHUK

DEFINING THE WORLD... 4 techUK represents the companies and technologies that are defining today the world that we will live in tomorrow. More than 850 companies are members of techUK. Collectively they employ more than 500,000 people, about half of all tech sector jobs in the UK. These companies range from leading FTSE 100 companies to new innovative startups. Tech UK membership covers both the large and multinational technology organisations and small and medium-sized businesses. Few sectors move and change as quickly as digital technology and its trade association has evolved to keep in step with the sector Intellect, techUK's predecessor which was formed in May 2003 as a result of a merger of the Federation of the Electronics Industry and the Computer Services and Software Association which brought the worlds of hardware and software together into one association. Ten years later, Intellect has been renamed techUK to better reflect the accelerating pace of innovation and to support an increasingly diverse base of growing tech companies operating across the economy and across the UK. As a trade association representing technology companies, techUK has a long heritage dating back almost 100 years. Successive waves of innovation in wireless technologies; electronics; computing; and software often originating in the UK have re-shaped the world we live in. techUK believes that to ensure jobs and growth in the future the UK has to be amongst the world's most advanced digital economies. This means that it needs to be a leader in both the development and use of digital technology for the benefit of the UK economy and its citi22

techUK members collectively employ more than 500,000 people, about half of all tech sector jobs in the country zens. This vision inspires and informs everything that techUK does. techUK is committed to helping its members grow, helping the sector grow and helping the wider economy grow through the smart use for tech. To this end, techUK activities are specifically designed to support its members’ efforts to develop markets, develop communities and networks and to reduce business costs and risks associated with operating in the UK. techUK programmes are designed around vertical and cross market areas of work which we are pursuing on behalf of the tech sector. The programme grid demonstrates the breadth

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of techUK work and indicates where organisations can get involved with techUK In order to derive value. techUK’s vertical groups are segmented into technology for Government and technology for business and consumer markets. Within this framework, our programmes revolve around key markets where technology is seen as a driver of economic growth in a digital economy. Every year, techUK works with its members to identify the most important issues that cut across the vertical programmes. These add context and relevance to techUK work. The UK’s reputation for innovation is renown throughout the world. Despite the emergence of low cost economies to manufacture volume product, the UK has carved a niche for high value, innovative products and systems. The UK’s technology sector includes major brands for high end quality products, and excels in the supply of systems, sub-systems, assemblies and components.

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MANUFACTURING & ENGINEERING TECHUK Technology has also changed the way we conduct global business, and we now see the emergence of small and medium sized companies now capable of delivering innovative solutions at a global level. Multi-nationals have also taken note, and now regard the SME and academic communities for new ideas through Open Innovation and Technology Scouting. In turn, this is changing the role of networks and trade associations in efforts to broker engagements, creating new business opportunities and collaborative partnerships. A key component of techUK’s electronics programme is the Electronics technology Network (ETN) - the UK’s largest technology network. The network has over 6,000 members (comprising 15% academics and over 4,300 businesses) and a strong focus on SME services (95% of members are from small or medium-sized businesses). The programme brings together for the first time, under one umbrella, a network of individual experts from the network with a corporate trade association. techUK is the first organisation to connect the supply and demand in the innovation space enabling technology scouting from the large multi-nationals

and brands, and offering channels to market for SMEs and academia. The UK cannot rest on its laurels as the champion for global innovation; there are many suitors for this title. The UK also has some underlying traits to manage regarding its capacity; specifically, how to enable its talented technology SMEs to deliver their product into global markets, reducing the risks associated with “the valley of death”. Great ideas and innovations come to nothing unless they find a route to market, and this is the challenge that techUK can overcome.

“techUK’s programmes are designed to enable the UK technology industry to realise its true potential”

Conversely, this is also an opportunity, as multi-nationals and global brands begin to realise that the most effective way to develop their innovation programme is to open up their challenges to a wider network to resolve. Whether this is framed as Open Innovation or technology scouting, the result is outcomes are usually the same, where SMEs find partners to develop their innovations into commercial products, and multi-nationals reduce their R&D costs, and innovation cycle time, by engaging in B2B brokerage with SMEs and academia. techUK, with The Electronics Network, is well positioned to facilitate Open Innovation and Technology Scouting; one of the key reasons why techUK leads the Innovation work stream, liaising with Government through the ESCO group. techUK’s programmes are designed to enable the UK technology industry to realise its true potential; that UK electronics, manufacturing and design will continue to be internationally recognised for both creativity and innovation, enabling commercial growth through new business opportunities, and increased domestic jobs that reflect a strong and vibrant sector. In addition to our extensive programme of activities, techUK members enjoy access to a growing number of services that have been created to help members refine, grow and develop their businesses. These range from meeting space for up to 120 people conferences as well as smaller business meetings, business building services, quality accreditation schemes and HR and legal advice. Additionally member business resources include market insights, reports and regulatory consultation documents as well as a wide variety of member discounts that cover training and development, software validation and Escrow services.

For more information on techUK programmes of activity, technology news, views, insights and services visit: www.techuk.org

FOR TODAY & TOMORROW.

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Next Gen.qxp_feature 2 11/06/2015 14:55 Page 24

MANUFACTURING & ENGINEERING NEXT GENERATION DATA UK

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MANUFACTURING & ENGINEERING NEXT GENERATION DATA UK

FOR THE WORLD

new generation data uk established to offer a data centre especially for this new world

Founded in 2007, Next Generation Data (NGD) UK was established in response to the changing nature of the data market whereupon a drastic fall in the price of connectivity for data centres allowed for the establishment of centres across the UK – not just in London. With the increasing need for power also becoming a concern within the London area, NGD realised the potential for establishing data centres in locations with secure sources of power, away from the hustle and bustle of London. The organisation has prospered ever since, going from strength to strength. As a pioneering technological innovator, NGD was one of the first organisations to spot this change in the market and therefore laid down the foundations for the new, evolved UK data market. It is this ingenuity, understanding and adaptation to market insight which has truly set NGD apart from its competitors and enabled it to secure major contracts from multinational organisations including BT, CGI and Wipro. Though the market has indeed changed in response to pioneering organisations such as NGD, it is NGD that is at the forefront of the UK data market, leading it into the future and beyond. “We're pretty unique. I think the trends in the market have followed what we're doing. People are now looking for sites with more power and space. All the data centres in the market used to be centralised around docklands, but now people are looking much further afield... I think we're still very unique considering the scale of what we've done but others have definitely followed,” explains Nick Razey, CEO of Next Generation Data. Also commenting on what truly makes NGD special, Brian Popperwell, NGD’s COO, explains: “The facility itself is pretty impressive in terms of scale,

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MANUFACTURING & ENGINEERING NEXT GENERATION DATA UK

“while the company has grown significantly since its establishment, NGD is a company with a keen focus on profitable growth, and not simply growth for the sake of increased revenues”

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MANUFACTURING & ENGINEERING NEXT GENERATION DATA UK

appearance and is also well maintained and looked after – after all it is our business. It's also all about the ethos of the company - a real 'can do' sort of attitude - and the kind of people that actually work here. It sounds cliché, but it's true.” Though currently in charge of a vast array of ground-level activities for NGD, from the client facing activities through to the back-of-house operation of the data halls, security and engineering, Brian himself originally came from a client of NGD's. Having previously worked with NGD as a result of this, Brian is one of the few people capable of not only understanding the specific needs of the client, but also how NGD can tailor its service to meet those needs – this is a result of his experience on both sides of the fence. Additionally, it is a credit to NGD's name

that its service should be so inspiring that those who work 'with' NGD may find themselves wanting to work 'for' NGD. Of course, while the company has grown significantly since its establishment, NGD is a company with a keen focus on profitable growth, and not simply growth for the sake of increased revenues, as Nick states: “We're not in favour of the 'build and they will come' speculative idea.” As a result, the company has seen turnovers grow by about 30% per year, but has made a conscious effort not to grow at a pace beyond the boundaries of efficient management. Though this does mean that the company has not perhaps expanded as quickly as it potentially could, it does however mean that the company operates as a very lean, efficient and profitable corporate machine. Most recently, NGD invested a further £8M in building five additional data halls at the data centre having won several new major client contracts. The importance of efficiencies run all the way through how the company operates of course, with plans for solar panelling on NGD's data centres so that the company can generate its own power as well as seeing heavy investment into management and efficiency technologies for the buildings themselves. With a considerable chunk of the UK's energy use being attributed to data centres such as NGD's, it goes without saying that efficiencies such as these are now a core part of successfully running a network of data centres, which is something NGD truly does best. “One of the first things our customers ask us is 'How efficient are you?' This means that being green is actually a competitive advantage for us,” comments Nick, who is incredibly proud of NGD's reputation for being the first data centre in the UK to buy 100% green power and establish key market benchmarks for the sector. Nick explains further how NGD has brought on board new technologies to help with the management of its centres and improve overall efficiencies and transparency: “We work very closely with Schneider

Electric. We've tried to standardise on Schneider equipment on the build side and one of the benefits of that is that we get to use their building management system which gives you a fantastic visibility of all your infrastructure and you have, at your fingertips exactly what's happening with every single piece of infrastructure whether it be generators, batteries, UPS or switchgear. You can literally see what's going on in the building and when you have a huge building like we have when it takes you ten minutes from one side of the building to the other, visibility is very important.” In addition, key to the nature of the technology industry is health and safety. There is of course, no excuse for organisations operating in such high-tech and high-powered facilities not to invest time and money into ensuring correct standards for health and safety, which is something NGD very much recognises. By putting its operatives through NEBOSH training as well as seeking additional support from key contractors, NGD is able to ensure that a full safety ethos runs through the company from top to bottom. Through working with key supply chain partners, in addition to associations such as techUK, NGD is also able to keep abreast of the latest technologies, developments and changes in legislation industry-wide, as well as benefiting from techUK's own dedication to support and protecting the interests of the wider sector. Of course, as keeping ahead of changes in the sector is precisely what has enabled NGD to continue delivering industryacclaimed solutions, it goes without saying that the support of such organisations is integral to how NGD operates. Looking to the future, NGD has its sights set on continued, sustained growth and given the dynamic state of the data market, who could argue with that? “We now all live in a digital word. We take it for granted in a way. These iPhones smartphones and tablets are fairly recent things, but as a result we do live in a world where data centres are almost like the factories of the 19th century. They are growing like crazy and they're becoming very important places... it's an industry that can only grow and there's one thing for certain – there will be more data generated this year than ever before,” explains Nick.

www.nextgenerationdata.co.uk

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Prism.qxp_feature 2 11/06/2015 13:15 Page 30

MANUFACTURING & ENGINEERING PRISM ELECTRONICS

FOCUSSED ON YOUR NEEDS

Prism Electronics, since its establishment 25 years ago, is a company that always tries to put the interests of its customers first – and it pays off. Many of Prism’s customers have stayed since the very beginning, with their contract electronics manufacturing services provided by the company to the highest standard possible. “Everything we do is customer led – customer is definitely king,” said David Dickin, Prism’s Business Development Director. “We see no reason why customers we have now wouldn’t keep buying from us for as long as they need to. Our focus when engaging with new customers is to make sure there’s a good fit there as well as us being able to demonstrate where we can add value to their business we’re looking for sustainable business relationships rather than just the next job.” Last year the company experienced a 25%

sales growth after a tough period of recession, with around £200,000 being invested back into the company for new equipment, improving productivity and extending capacity by roughly 70%. Prism offer a range of services in the contract electronics manufacturing (CEM) sector from start to finish – including design support, materials management, production and testing of products, and even distribution and logistics services in the post-production stage. This comprehensive service is what keeps customers coming back time and time again, no matter how challenging the request. “Some of the things we do are quite complex – but we’re never afraid of taking on a required process for a customer. Often things haven’t been done before, so we carefully assess, derisk it, and make sure we do it right. We’re often working closely with our customers because they’re sometimes asking for things which are a

With a focus on the flexible manufacturing of modest volumes of complex products, Prism harnesses production and engineering resources to add value to your designs and help you to create successful products. 30

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MANUFACTURING & ENGINEERING PRISM ELECTRONICS

little bit unusual,” David Dickin told us. “We’re a small company but we’re able to offer flexibility and personal service, while having the kind of structural backbone expected of bigger companies.” Prism’s vision and goal is to be a business which is valued and trusted as a first class manufacturer, sustains profitable growth, encourages open and honest long-term relationships, and offers rewarding employment where people can take pride in their achievements. “Everything we do is driven by our vision statement – it’s not just there because it needs to be, but because we believe it ,” said David. “Our key assets are the people and the processes, and we invest heavily in both. All

our operators are trained and certified to IPC 610 by our IPC certified in-house trainer. They are supported by comprehensive IT and process facilities and of course it goes without saying that the health and safety of all employees is paramount.” Prism has achieved ISO9001 Quality Management certification, ISO14001 Environmental Management certification and is an accredited Investor in People, helping them to gain more customers and ensure standards are maintained throughout the company. As a member of TechUK, Prism experiences a variety of benefits. David explained; “TechUK is the leading trade body for our sector. The thing that is important for us is to get the sta-

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MANUFACTURING & ENGINEERING PRISM ELECTRONICS

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MANUFACTURING & ENGINEERING PRISM ELECTRONICS

tistics from them, as well as networking with both competitors and customers which is always useful. It’s fairly important because electronics these days are at the heart of everything and with the UK being a hotbed for innovation, fledgling companies and start-ups wouldn’t be able to get as far without local support from manufacturing bodies. I’d say TechUK is probably the most focused representation of our industry that I’ve been aware of for many years – we make use of the member services that we’re entitled to as we need them, we attend meetings and networking events… it’s good for us.”

Last year, Prism won Highly Commended: Judges’ Special Award at the Cranfield School of Management Best Factory Awards for their work in the CEM field. On top of this, the company had been awarded Most Improved Factory at the BFA Awards in 2005, and it continues to re-enter every year - not with any expectation of winning a specific award, but for the benchmarking feedback given by the awarding body. The benchmarking runs across a wide range of industries and sectors with big name sponsors and competitors such as Toyota, Coca Cola, and Sony. “Whether or not we receive additional

“Last year, Prism won Highly Commended: Judges’ Special Award at the Cranfield School of Management Best Factory Awards for their work in the CEM field” interest from prospective customers as a result of our awards - which we have - we will keep entering for the valuable benchmarking we receive,” said David on the subject. “Where we like to differentiate ourselves is in providing the best service. Our customers value what we do and continue to tell us that via the twice-yearly independent customer surveys we do – we send them out every six months to everybody we deal with in every organisation that we sell to. We just had responses back from the last survey – the average scores say that we exceeded their expectations in all areas.” For example, a Large independently owned company described Prism as providing “great service, great quality”, and another said “Prism continue to deliver an unparalleled level of service in all aspects of supply.” It is this continued high level of excellence, combined with their personal approach to customers, that have kept many of Prism’s clients with them for so long – and it is their constant innovations that keep their business competing with the top CEMs. It seems the company will continue to grow for years to come in the face of fierce competition. www.prism-electronics.com

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Explosive Engineers.qxp_feature 2 09/06/2015 12:57 Page 34

MANUFACTURING & ENGINEERING INSTITUTE OF EXPLOSIVE ENGINEERS

Established over 40 years ago, the Institute of Explosive Engineers (IExpE) was established with the singular goal of promoting competency, education and professional standing for all those who work in and around the area of explosives. The IExpE has a very broad membership range, covering professionals from a range of industries including: demolitions, quarrying, forensic explosives, fireworks, special effects and a whole range of defence munitions. Much of the strength of the institute is in fact founded on the diversity of the disciplines of its members, of which research shows that it contains some 25 differing disciplines across 20 industry sectors. Over the course of the past few years the IExpE has made great progress in supporting the competencies of individuals in explosive skills through the creation and utilisation of National Occupational Standards (NOS) for Explosives, Substances and Articles which can be found on the NOS website. In conjunction with some of the large defence manufacturers, the IExpE has established a Sector Skills Strategy Group (SSSG) which effec-

ENGINEERING

EXPLOSIVES the institute of explosive engineers promote the occupational competency, education and professional standing of those who work with explosives tively funds and tasks a Development Office for Explosive Skills and co-ordinates several Expert Working Groups to share best practices across the explosives industries. In realising its core mission statement for competencies, education and professional standing, the IExpE pursues a number of core initiatives to support the wider sector. By providing comprehensive education, training and examination services for the highly specialised fields of its members, IExpE effectively supports the continued 34

improvement of training and standards throughout the sector. To support its ability to communicate and foster excellence within its members, the IExpE has also established an effective Secretariat, Council, Committee and Working Group structure to ensure prompt, efficient communications between the institute, its membership and outside organisations so that all explosives industry stakeholders can be kept up to date and can effectively work in cooperation. IExpE is also a Professional Affiliate of the Engineering Council and is encouraging

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MANUFACTURING & ENGINEERING INSTITUTE OF EXPLOSIVE ENGINEERS

“IExpE effectively supports the continued improvement of training and standards throughout the sector”

its membrs to become professionally registered. The scope of its membership has been broadened recently to offer young people undergoing education and training in explosives or explosives-related skills to become student members at heavily discounted rate. This then effectively gives them access to the IExpE members are where they can log into “My Career Path” and record all their CPD, which is vitally important if they are aspiring to professional registration. The IExpE also partners with a number of industry-relevant organisations in setting standards for the explosives industries, including key partner, the SSB. Established in 2000 to develop NOS and National/Scottish Vocational Qualifications (N/SVQs) for sue in munition clearance and search occupations. Due to the natue of this area of work, the SSB is seen to work very closely with the Armed Forces and other government agencies with a few nongovernmental and commercial organisations slowly becoming more increasingly involved over the years.

www.iexpe.org

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Spex.qxp_feature 2 10/06/2015 11:42 Page 36

MANUFACTURING & ENGINEERING SPEX GROUP

ENERGETIC INNOVATION

In an industry constantly coming up with new challenges, requiring innovation, it can be difficult to keep up. But SPEX, founded in 2009, is continually developing services and products to aid the challenges that the global oil and gas industry may face. Problems can create unwanted downtime, disrupt production and cause major financial loss – SPEX is committed to solving these problems and any other challenges that a project may present using a wide range of energetic material, suitably applied delivering solutions for drilling and production, and abandonment and thereby optimising their client’s assets. “Every service and innovation SPEX develop and deliver is steered by our dedicated Project team. The principal aim is to ensure all deliverables are met in a timely fashion and to a standard that exceeds our clients' expectations. Since SPEX provides services and innovation to the global oil and gas industry, we have established strong project alliances with our clients throughout the world.” SPEX offers bespoke explosive solutions to the worldwide oil and gas industry, combining their intimate knowledge of engineering physics, thermodynamics, and chemistry, to formulate the optimal solution. “We have a myriad of different clients and operating environments, which are all added values for us because it means that we’re not just doing one thing. One day we’re working with the police and training them, one day we’re working in Saudi Arabia and the next day we’re working in the North Sea. We have a global footprint,” said Andrew Pettitt, Co Founder and Business Development Director of the company. Last year SPEX won Best Newcomer Award at the Business Insider SME300 Awards 2014. The Awards were founded to recognise the importance and achievements of Small to Medium Sized enterprises in Scotland. "SPEX has developed rapidly since it began

SPEX offers bespoke explosive solutions to the worldwide oil and gas industry, combining their intimate knowledge of engineering physics, thermodynamics, and chemistry only six years ago and applying innovation has been the key driver behind our growth. We are a knowledge driven company and invest significantly in Research and Development, recruiting the best talent and aligning closely with our clients to create turnkey solutions for their technology problems and provide game-changing products,” said Chief Operating Officer of SPEX, Nadir Mahjoub. Investment firm BGF invested £5m into SPEX in March last year, giving them a minority stake in the business. BGF’s Investment Director Mike Sibson said the investment was

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“a great fit for BGF” as "SPEX has built an excellent position based on a unique set of skills, and has exceptionally strong engineering capabilities. It has an ambitious team with a vision to build an international business." The investment will continue to help SPEX accelerate their already rapid growth, and will assist in the development of new tools and systems as well as enabling an expansion of their current capabilities. “As well as our hands-on explosives use, we do forensic analysis and investigation, recognised explosives training which qualifies for

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MANUFACTURING & ENGINEERING SPEX GROUP CPD points for those following structured career development, and strive to provide best-in-class solutions for whatever the specific application,” said Andrew Pettitt. The company has designed a system to cut large, solid pieces of metal, known as drill collars following the 2010 Gulf of Mexico oil spill. At that time there was an absence of suitable technology to fix the problem, which is something SPEX is currently rectifying with their new unique explosive tool configuration called the Blowout Emergency Severance Tool (BEST). Operating at water depths of up to 10,000 feet, the BEST is designed to go into action in the case of an emergency situation, effectively cutting through previously unshearable obstructions and allowing the pipe or ‘well’ to be sealed successfully – avoiding such a disaster again. SPEX have also invested heavily into a new custom super computer titled ‘The Claymore’ with a processing speed of over 100 trillion operations per second – which allows the company to model and test components in an FEA (Finite Element Analysis) simulated environment, thereby enhancing their reliability and reducing the timeframe of designing and delivering products to market drastically. They’ve also managed to reduce the amount of explo-

sives needed for particular applications providing welcome environmental advantages. It is innovations like these that have won the company some of the top accolades in their industry – including placing fourth on the Sunday Times Hiscox Tech Track 11 league table, and winning the Technology Innovation of the Year award at the National PwC/HSBC Private Business Awards in London, 2013, in recognition of their developments regarding the BEST. When asked of the aims of the organisation for the coming years, Barry Chapman, Co Founder and Operations Director told us; “It’s quite simple; we want to be seen as best in class for what we do in the sectors we work in. Within the portfolio of services that we have, we can offer advice, support and services to everyone from major international oil companies with global footprints to smaller entities.” Andrew Pettitt went on to say; “We believe explosives are a precision tool and along with other technologies in the toolbox offer a wide range of engineering applications;. We’re very pleased with where we are in 2015, and looking ahead hope to see more unique and diverse uses of our capabilities” www.spex-innovation.com Tel: 01224 72784

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Romag.qxp_feature 2 09/06/2015 13:00 Page 38

RAIL ROMAG

A BRIGHT FUTURE

as one of the most experienced bespoke glass solutions providers, romag have been manufacturing in the North East of England since 1943.

Specialising in the manufacture of bespoke glass and photovoltaic (PV) products, Romag is committed to supplying high quality technical products to their diverse range of clients. A wholly-owned subsidiary of Gentoo Group, Romag manufactures anything from bullet, resistant triple glazed windows to double-curved train windscreens. Furthermore Romag are leading the way when it comes to building integrated photovoltaics (PV) – which generate renewable energy - and have innovated a range of PV tiles which integrate the technology seamlessly into both domestic and commercial buildings. “Our innovation has been inspired by our customers’ changing needs. As energy prices continue to rise we will soon be in a position where solar power will achieve grid parity in the UK. This means that solar makes financial sense and we will see more being incorporated into the fabric of buildings.” On-roof PV systems are effective but aesthetically they do not sit comfortably with our house building customers. All major house builders are now demanding the technology be incorporated into the roof space so their homes are attractive to sell. Here at Romag we have

been the preferred supplier of roof integrated PV systems for many years as we understand the need to ensure the PV tiles perform as a building product as well as a solar module. This year we have introduced the innovative ‘Intecto’ range of coloured, frameless PV tiles to the market to colour match and course seamlessly with the current range of concrete tiles. The Intecto tile been designed to incorporate the majority of fixings needed to secure the tiles on to the roof which means it’s the simplest and quickest roof-integrated PV system on the market to install. The final product is so good that you ‘d need to look twice to notice the PV in the roof!” said Deputy CEO of the company, Phil Murray. “In order to raise product awareness we’ll be exhibiting at this year’s major PV exhibitions. In June we’ll be exhibiting at Intersolar in Munich and then in October at Solar Power UK in Birmingham.” Recently, Romag secured a contract with Bombardier for their Crossrail trains, beating off competition from both Europe and China. “Romag is delighted to have secured this prestigious, long-term supply contract for train windscreens for Bombardier’s new Aventra platform. Initially 130 trains will be supplied to Transport for London for Crossrail and we will begin full scale production of the windscreens

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this August. This contract win is further testament to Romag's ability to work closely with our customers to develop bespoke glass solutions to resolve complex technical problems.” The product features a large curved windscreen specifically designed to travel at high speed while protecting the driver and passengers from impact from stones or birds. Romag has also been working closely with JCB Defence to provide ‘transparent armour glass’ for military vehicles, a glass designed to with-

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RAIL ROMAG

stand the highest levels of attack, including those from armour piercing bullets. Given its interest in PV solar solutions, itâ&#x20AC;&#x2122;s hardly surprising that Romag is very interested in sustainable technology and is striving to reduce its own carbon emissions. Its carbon footprint has reduced significantly over the past four years and none of their waste goes to landfill. Any profits made also go straight back to their parent company Gentoo Group, who invest the money into local communities including education programmes, healthcare, and quality affordable housing. The company is also ISO9001, ISO14001 and ISO18001 accredited, ensuring quality, safety and environment systems are both robust and properly managed across the business. As lovers of challenge and innovation, Romagâ&#x20AC;&#x2122;s credentials and capabilities really set them apart from their competitors. Their commitment to creating the highest quality, bespoke products is admirable and the company hopes to expand its network of partners in the future, finding solutions to complex problems wherever they may be needed.

www.romag.co.uk Contact: sales@romag.co.uk Telephone: 01207 599000

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Railtex.qxp_feature 2 03/06/2015 14:49 Page 40

RAIL RAILTEX 2015

RAILTEX 2015

IS A SUCCESS The latest technology, equipment and innovations were exhibited at the most effective Railtex for years Nearly 7,500 rail industry professionals visited the recent Railtex 2015 exhibition at the NEC in Birmingham from 12 to 14 May. A total of 468 leading suppliers took part in the successful show, presenting their latest technology, equipment and innovations during an event regarded as the most effective Railtex for years. Participants included many of the best known firms supplying the UK rail market. There was a high-profile presence by Bombardier Transportation, which is currently delivering new trains for London Underground and Thameslink, Southern & Great Northern, and will soon be supplying rolling stock for the capital’s Crossrail project. The Hitachi Rail Europe stand featured a model of the intercity trains the firm is to build at its new County Durham factory for the Department for Transport’s IEP programme, plus its vehicle concepts for future UK high-speed lines. Also present was Siemens, which will deliver the first new Thameslink trains later this year and is also

supplying new trainsets to Eurostar. They were joined by a vast range of highly specialised companies covering every sector of a very diversified supply chain. While British-based companies predominated, there was an increased presence by foreign companies seeking opportunities in a UK rail market that is enjoying unprecedented levels of investment. Most notable were exhibitors from China, principally train builders China CNR Corporation and CSR Sifang, soon to be merged to form the world’s largest rolling stock manufacturer. The latter company chose Railtex for the official signing of cooperation agreements with three leading UK universities to establish a centre for railway research and development. Of the 7,449 trade visitors attending the show, over 73% were of senior manager level or above and possessed purchasing power. As a result, many exhibitors said Railtex exceeded their expectations, with show surveys indicating that 98% received positive

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RAIL RAILTEX 2015 business enquiries. While the event continued to fulfill its primary role as a showcase for the latest in railway technology, it also featured an extensive and high profile range of supporting activities, providing further Railtex highlights. These included technical seminars plus a full programme of interactive sessions including project updates, industry briefings and discussion forums. Many featured presentations by leading figures shaping the UK rail sector and all were free to attend. The popularity of these sessions meant that many were standing-room only, including those

by the recently formed Rail Supply Group set up by the industry and government to optimise the potential of UK companies. The Group’s cochairman Terence Watson said: “Railtex provided the RSG with an unrivalled opportunity to engage with both the industry and its customers. With access to over 2,700 representatives of exhibitors and almost 7,500 visitors over the three days, we were able to share the RSG’s vision for the future; and also outline how businesses in the supply chain, both large and small, could work with us as we develop our Industrial Strategy. Railtex will form a key

part of our engagement with the industry over the coming years.” More information on Railtex 2015 can be found at www.railtex.co.uk. Meanwhile, planning is now well under way for the next UK rail show organised by Mack Brooks Exhibitions Infrarail 2016 covering railway infrastructure equipment and technologies will take place at ExCeL in London from 12 to 14 April next year. It will be co-located with the company’s CITE – Civil Infrastructure Technology & Equipment event. Visit www.infrail.com and www.cite-uk.com for details.

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FOOD & DRINK BRITANNIA KITCHEN VENTILATION

Experience and expertise count for nothing if a business cannot deliver a reliable and effective solution for its customers’ needs. Britannia Kitchen Ventilation, based in Warwickshire, has built its reputation on consistently achieving the desired result. Since its inception in 1995, the company has developed a portfolio of satisfied clients and end users that has established its industry leading reputation. While it has been a challenge gaining a strong foothold in the marketplace, success has been achieved thanks to a rather simple case of marrying expertise with a product range that makes a positive difference. With some of the industry’s most experienced people, the company enjoys an intimate knowledge and understanding of its clients’ needs, meaning it is adaptable to varying requirements. In addition, 42

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thanks to attentive customer service, a wide range of quality products and affordable prices, Britannia has become one of the UK’s most sought after suppliers of commercial and institutional kitchen hoods and ventilated ceilings. Customers benefit from a holistic approach that includes a full design and consultancy serv-

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ice, through to manufacture, delivery and complete installation, all backed up with professional indemnity insurance cover. This is supported by Britannia’s sales and technical teams ensuring clients receive the correct selection and sizing for any given situation. Indeed, Britannia has the most comprehen-

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FOOD & DRINK BRITANNIA KITCHEN VENTILATION sive range of commercial kitchen ventilation solutions from bespoke solutions, Britstream, Capturestream and Econex Canopies, Mistream water-mist hoods, Ultrastream UV hoods, Refresh recirculating units, Silverline and Heydal ventilated ceilings, Services Distribution Units and Splashbacks. And through its dedicated development programme, the company ensures continuous improvement encompassing an R&D department which regularly brings new products to an ever-changing market. Quality is often judged on reliability and if that’s anything to go by then Britannia’s offer of a 10-year warranty on its Britstream product line signifies the company’s confidence in the equipment. Product innovation has also proven crucial to Britannia’s growth, with the development of ‘Refresh Ultima’ recirculation range. Having extensively re-engineered the product to incorporate new technology, Refresh is the only recirculating unit to have been installed at over 70 sites

“Customers benefit from a holistic approach that includes a full design and consultancy service, through to manufacture, delivery and complete installation” throughout the UK and is ideal for providing commercial kitchen ventilation solutions where ductwork routes to atmosphere are restricted. Prestigious installations include: Heathrow Terminal 2 & 5, Prêt-A-Manger, Yo Sushi, Marks & Spencer’s, BBC, JP Morgan and Cappuccino. Refresh is a self-contained unit requiring no direct duct connection to atmosphere and works using multiple stages of highly efficient particulate and odour filtration. Typical applications would include sports stadia, airports and railway concourses, existing installations where additional capacity is required and listed buildings where planning restrictions preclude the use of traditional ducted systems. Production Manager Jim Dixon said, “We always aim to stay at the forefront of innovation in kitchen ventilation and this range of products demonstrates our commitment to investing in the development of new ideas.” Andrew Galeckyj, Commercial Director added: “We at Britannia work hard to foster a creative atmosphere, we have a strong team with a wealth of experience and technical knowhow, to solve problems, engineer solutions and assist with design, from a basic system to a complete solution.

www.kitchen-ventilation.co.uk Tel: 01926 463 540

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SCCS.qxp_feature 2 04/06/2015 16:48 Page 44

CIVIL ENGINEERING STEEL CONSTRUCTION CERTIFICATION SCHEME

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CIVIL ENGINEERING STEEL CONSTRUCTION CERTIFICATION SCHEME

ENCOURAGING QUALITY & PRODUCTIVITY The SCCS was established in the early 1980s to provide a Quality Management Systems certification service for steelwork contracting organisations

There is a case for steel in all construction scenarios. There is a solution for all projects and the different engineering requirements that they bring, such as fire protection, thermal insulation, acoustics, vibration and BREEAM excellence. Whether it is hospitals, housing, schools, offices, mixed use, warehousing, bridges, power generation, there are abundant examples of where steel has been the preferred choice. The Steel Construction Certification Scheme (SCCS) is a wholly owned subsidiary of the British Constructional Steelwork Association (BCSA). It was established in the early 1980s to provide a Quality Management Systems certification service for steelwork contracting organisations. SCCS has subsequently developed additional certification and monitoring services for the steelwork contractors with integrated or separate environmental and health and safety management systems and factory production control systems. The directors are committed to the principles of impartiality in carrying out

management system certification activities, management of conflict of interest and ensuring objectivity of the management system certification activities. Quality management systems operated by the certified contractors' are formally assessed to ensure compliance with the requirements of ISO 9001:2008. Each certificate issued is valid for three years during which period SCCS conducts regular surveillance audits to monitor continued compliance with the certified management system. Meanwhile, environmental management systems operated by the certified contractors' are formally assessed to ensure compliance with the requirements of ISO 14001:2004, and occupational health and safety management systems operated by the certified contractors' are formally assessed to ensure compliance with the requirements of BS OHSAS 18001:2007. The BCSA, of which SCCS is a wholly owned subsidiary, is a national organisation for the steel construction industry. Its member companies undertake the design, fabrication and erection of steelwork for all forms of construction in

building and civil engineering. Associate members are those principal companies involved in the direct supply to all or some members of components, materials or products. Corporate members are clients, professional offices and educational establishments which support the development of national specifications, certification services, fabrication and erection techniques, overall industry efficiency and good practice. The principal objectives of the association are to promote the use of structural steelwork; to assist specifiers and clients; to ensure that the capabilities and activities of the industry are widely understood and to provide members with professional services in technical, commercial, contractual, quality assurance and health and safety matters. The association's aim is to influence the trading environment in which member companies have to operate in order to improve their profitability.

www.steelconstruction.org Tel: 020 7839 8566

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Icarus.qxp_feature 2 18/06/2015 12:53 Page 46

CIVIL ENGINEERING ICARUS LIGHT STEEL FRAMING

SETTING THE TREND

Icarus design, manufacture and install light steel framing for a number of clients including major players such as Carillon, Galliford Try, Wilmott Dixon and Henley Homes

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CIVIL ENGINEERING ICARUS LIGHT STEEL FRAMING

Icarus LSF is setting the trend in all aspects of light steel framing within the construction sector. The Icarus approach is to drive sustainable business opportunities by working collaboratively with clients to foster long-term partnership. This is achieved through a wealth of expertise and innovation within Icarus to assist and guide clients through the mutual journey. The company’s business is designing, manufacturing and installing light steel framing, which is undertaken for a number of clients including major players such as Carillon, Galliford Try, Wilmott Dixon and Henley Homes. Recent projects include a load-bearing light steel frame structure for student accommodation, two load-bearing structures to form a hall and education block for a primary school and various apartment and housing schemes throughout the UK. Although the company provides a wide

range of service to clients with light steel framing requirement, the preference, according to CEO Zac Hussain, is to be involved early and fully within a 360 framework: “We engage at the outset to discuss a scheme and take part in design team meetings. That ensures we are working collaboratively as a team with our clients and transparent with the scope of works so we can manufacture bespoke engineered solution to our clients’ requirement and ultimately deliver and install in a timely fashion. “As part of our customer journey, we provide installation service as a one-stop-shop-solution to maximise overall quality in line with the mutual programme with our clients. We want to engage with clients from the initial receipt of an enquiry through the design process, manufacture and full installation to complement mutual programme. Based on our expertise and know-how in the market, this is exactly what clients require because they have the peace of

mind of giving it to an expert who can deliver according to plan from start to end.” That approach means it can, if required, provide elements within a light steel frame structure such as walls, floors, roofs, stairwells, stairs, lift shafts, walkways and balcony supports. It’s the same approach that made it the official contractor for light steel framing at the London Olympics after providing bespoke solutions for food concession buildings. When all other options from alternative sources could not deliver the client’s requirements, Icarus was requested to review the scheme and provided a bespoke solution meeting and exceeding the client’s design requirements. This ability to solve the client’s problems led on to several further opportunities within the Olympic development providing rapid designs and manufactured products within 24 hours of the opening ceremony.

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CIVIL ENGINEERING ICARUS LIGHT STEEL FRAMING “We are very flexible and can work to a client’s requirements in a very structured fashion,” confirms Zac. “Our strapline is ‘Quality First, Quality Matters and Quality Lasts’, something we live by in every aspect of the organisation. It applies to our workforce as well as all business functions such as manufacturing to ensure zero defects, logistics to ensure on-time delivery and a world-class cus-

is delivered in accordance with the design parameters to the desired quality. Delivery to site sees reduced construction times on site and taking advantage of the stability and durability of Light Steel Framing gives the customer the ability to start follow-on trades at advanced stages, further reducing on-site programmes whilst in the long term the dry and stable properties of Light Steel framing

“All design and manufacturing is undertaken at the company’s new 48,000 square foot state-of-the-art facility in County Durham, where Icarus has moved due to rapid growth” tomer service in every aspect of our client’s requirement. We have the skills, expertise, cando-attitude and the drive to go the extra mile to ensure a good service.” Light steel frame offers a competitive solution for all building options and by its name is lighter than traditional solutions giving potential savings in foundation costs. Using 3D modelling at the design stage enables Icarus to fully co-ordinate its design with the client to ensure the offsite element

reduce maintenance issues. All design and manufacturing is undertaken at the company’s new 48,000 square foot state-of-the-art facility in County Durham, where Icarus has moved due to rapid growth. Country-wide installation is handled by strategic partner I&S Construction, which works in conjunction with the wider project teams to provide quality installation services to clients. That set-up has delivered a successful

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start to 2015 that’s seen the company secure new contracts, work with major players and build on previous expansion. Zac says: “We have grown rapidly, have prominent and sustainable clients and we’re expanding as a team to drive the LSF sector to the next level. We make sure we are up-to-date with latest innovations and machines, can manage capacity and ultimately deliver long-lasting customer service.” Central to the growth plans is the new manufacturing facility, where three acres of additional land have already been purchased to allow for further expansion. “Our vision is to become the ‘preferred supplier of choice’ for all light steel framing requirements across the construction sector,” proclaims Zac. “For new clients with no knowledge of light steel framing, we want to educate and motivate them, give them the benefit and develop long-term business relationship. We will continue to deliver customer excellence in every milestone of our mutual journey to generate sustainable business. For further information, please contact us directly on 0191 594 7200 or email us at enquiries@icarus-lsf.com www.icarus-lsf.com

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CIVIL ENGINEERING ICARUS LIGHT STEEL FRAMING

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CIVIL ENGINEERING JCC ENGINEERING

LEADING FROM THE FRONT 4 JCC is firmly established as one of the South East’s foremost steel fabricators JCC Engineering has established itself as one of the South East’s foremost “local” steel fabricators. With capability to handle everything from 5 to 200+ tonnes, the company boasts its own factory and erection crews giving it the versatility to maintain projects all over London and the South East region. Formed in 1985, the company’s carefully managed expansion programme saw the opening of a facility in Birmingham in 1999 to cater for larger contracts. This increase in capacity has resulted in JCC Engineering’s current manufacturing facility totalling over 2,000 square metres. Capable of fabricating and erecting all manner of structures including portal frames, beam and column, lattice and a variety of other types, JCC prides itself on its ability to work with clients to understand their individual requirements. Dave Robson, QA manager, highlights a number of high profile projects undertaken successfully by JCC in recent years including one scheme in 2009

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that featured on Channel 4’s Grand Designs programme. The new four-storey mansion in Brighton was set in a prominent position overlooking the seaside city. Its prominent feature was a modern, multistorey steel-framed building of curved steel and glass. The project was trumped a couple of years later when JCC was involved in the Queen’s diamond jubilee river pageant. “We were fortunate enough to be asked to build a belfry tower structure for the leading vessel,” says Dave. “Standing approximately 5.400m tall and with a footprint of 6.300m x 5.800m, the belfry housed eight bells, specially cast by the Whitechapel Bell Foundry in London for the City church of St James Garlickhythe in London. “Working in close association with the Port of London Authority, the structural members were transported to a North Kent quay and assembled on the dockside, where the eight bells were installed and the structure was craned onto a traditional Thames barge - the 82ft Olympic Class Ursula Katherine.”

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CIVIL ENGINEERING JCC ENGINEERING

The company continues to go from strength to strength, attaining ISO9001 in 2013 and recently becoming BSEN ISO1090 (CE Marking) accredited to Execution Class 2. “Having an existing Factory Production Control such as ISO9001 was a good foundation for the additional welding and workshop procedures required for CE Marking,” remarked Dave. “We were helped greatly by employing the services of the Philip Bralsford Consultancy in Sheffield – a leading provider of professional consultancy, training, audit, inspection and assessment services to the metal industry. The Responsible Welding Co-ordinator course run by them was particularly comprehensive and formed an essential part of our learning process.” Importantly, the Steel Construction Certification Scheme (SCCS) has aided JCC in developing and improving its policies and procedures. “We found them to be very approachable and professional during their two stage audit assessment of us. They really appreciated all the hard work we had done in bringing all aspects of the CE Marking requirements together,” added Dave. “For many years, we had performed a majority of the required procedures relating to quality, prior to CE certification. The Quality Factory Production Control now makes it easier for us to maintain product traceability, which is an essential part in showing our clients that we do what we say we do. For many of our larger clients this is a fundamental requirement. “We educate many of our clients by providing them with product information and traceability, which not only provides them with peace of mind but complies with legal requirements. We continue to pride ourselves in providing a quality product and service to our clients.” www.jccengineering.co.uk Tel: 01732 862283

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CIVIL ENGINEERING LIONWELD KENNEDY

100 years of

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CIVIL ENGINEERING LIONWELD KENNEDY

The manufacturing sector has always been an industry where innovation and continuous improvement is essential. However, there are always companies that stand head and shoulders above the rest – this is the reputable steel flooring and handrail manufacturer Lionweld Kennedy Flooring - who are part of the Hill & Smith Group. Being at the forefront of product innovation and development Lionweld Kennedy sits at the pinnacle of quality products and service provision to many project types and requirements. Based in the north east of England, Lionweld Kennedy is a company built upon a foundation of excellence and experience for more than 100 years. The

company is unique in that it is the only UK manufacturer of steel gratings and it is a key player in offering steel and GRP flooring solutions as well as fabrications of platforms, ladders, stairs, pre-fabricated flooring, associated steelwork and an assortment of handrailing systems. Products are offered either as a modular “flat pack” for easy installation or alternatively, the company also offers a full project management and installation service for those wanting to tap into Lionweld Kennedy’s considerable expertise. Through a continuous cycle of product innovation and evolution, Lionweld is dedicated to pushing the boundaries of excellence through the utilisation of new technologies, facilities and design principles. With the addition of a brand new flooring machine and a modern, state of the art GRP fabrication facility, the

company has successfully developed and opened up new market sectors which depend on a quality product and service at a competitive price. Lionweld Kennedy’s GRP and steel hybrid rail platform is testament to its innovative culture. There are currently over 100 installations throughout Network Rail’s rail facilities and the company is dedicated to developing new systems such as trackside structures and location cabinet platforms, which are extensively used in the electrification and signalling projects across the UK in an attempt to sustain and grow on its success.

there are always companies that stand head and shoulders above the rest – this is the reputable steel flooring and handrail manufacturer Lionweld Kennedy

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lionweld.qxp_feature 2 11/06/2015 13:52 Page 54

CIVIL ENGINEERING LIONWELD KENNEDY

Lionweld Kennedyâ&#x20AC;&#x2122;s new flooring machine has allowed the company to supply an increasingly vast range of products in response to the growing needs of the modern customer. Responding quickly and efficiently to the needs of its clients, Lionweld Kennedy has developed its reputation of offering quality products, on time and to budget. The company's new GRP fabrication facility is equipped with CNC machines and the new steel workshop allows us to support our fabrication customers who from time to time do require fabricated products. This business model has enabled the company to go from strength to strength year on year. Through maintaining close working relationships with its sister company in the US, Creative Pultrusions, Lionweld Kennedy has been able to continually develop new innovative solutions in GRP including structural piling, ballistic tested wall panels, handrail and flooring systems, GRP cable trays, utility poles and a

myriad of other innovative products still in research and development. Key areas of development for Lionweld Kennedy UK include; the development and quality of its products and is continuous improvement philosophy of producing a cost effective product on time and to worldwide specifications. Being a part of a PLC Lionweld Kennedy takes corporate responsibility very seriously

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and as such, the company displays a proactive approach to maintaining high standards for health and safety for staff and stakeholders alike. Having achieved its 8th consecutive ROSPA Gold award, the company has shown clear expertise and diligence in maintaining standards for health and safety as well as realising its commitment to environmental protection and new quality benchmarks. Lionweld recently achieved BS1090 CE Marking accreditation which was a legal requirement on July 1st 2014. This has driven the company to establishing its own welding and quality engineering department, again demonstrating the company's commitment to being a market leader and ensuring full compliance across all its products and services. Lionweld Kennedy sees the export market as a being essential to the company's continued

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CIVIL ENGINEERING LIONWELD KENNEDY

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CIVIL ENGINEERING LIONWELD KENNEDY

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CIVIL ENGINEERING LIONWELD KENNEDY

growth and future success. Ian Kirkup the group’s Sales & Marketing Director for Lionweld Kennedy explains: “The brand is strong throughout the global market with not much marketing, therefore we now have to proactively develop these opportunities and promote the company outside the UK, our products are regularly specified by designers and we do secure work via this channel. With the benefit of a new flooring machine it is now time to capitalise on projects that we have secured in Azerbaijan on the Shaz Deniz 2 oil and gas project as well as developing relationships with customers in Asia and Europe.” Valuing its members of staff as the true backbone of the organisation, Lionweld takes an incredibly responsible approach to ensuring that all members of staff are correctly trained and kept safe at all times. With stringent health and safety training plans and diligence Lionweld Kennedy ensures all statutory requirements are met as well as encouraging a

conscious, pro-active safety culture throughout the workplace. The company also hosts an “open door” approach to safety through encouraging shop-floor involvement via safety representatives, senior manager safety audits and joint employee safety committees; this is to ensure that safety standards are consistent from top to bottom of the organisation. In addition to recognising the importance of its workforce, Lionweld Kennedy highly values its supply chain in a manner far more similar to business partners rather than “another supplier”. All suppliers utilised by the company are approved and vetted to ensure that the relevant organisations hold similar values and beliefs to that of Lionweld Kennedy. These companies are essential in supporting Lionweld Kennedy’s business goals and objectives and its “promise to the customer” Ian Robinson, Managing Director of the Lionweld Group explains: “Our supply chain plays a major part in the group’s success. For

example, Bromford Steel Company and Tube Trade supply the raw material competitively and to the desired quality, the Joseph Ash Group have galvanising plants nationwide, this gives Lionweld Kennedy the option of utilising these geographical areas for local projects, and even the supply of the right quality fixings and fittings is critical to our (JIT) approach. Both Global fasteners and Premier fasteners are two companies that are key in ensuring that their products arrive on site, on time and to the desired specification.”

Lionweld Group Marsh Road Middlesbrough TS1 5JS Tel: + 44 1642 245151 Email: sales@lk-uk.com Website: www.lk-uk.com

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CIVIL ENGINEERING CONSTRUCTION EQUIPMENT ASSOCIATION

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CIVIL ENGINEERING CONSTRUCTION EQUIPMENT ASSOCIATION

The Construction Equipment Association is the trade association that represents the UK construction equipment sector and is recognised by HM Government as the voice of the industry.

The Construction Equipment Association (CEA) has a membership that includes original equipment manufacturers with UK production facilities, overseas OEMs with UK offices, component and accessory suppliers, trade publishers, specialist service providers, equipment distributors, and some international companies. The association, which is recognised as the voice of the industry, provides members with all the typical benefits of a well-run sector association including technical and regulatory assistance, marketing strategy and promotion for both UK and international markets, lobbying, trade exhibitions and networking opportunities. Most recently, the CEA spoke positively of the government’s budget announcement, saying it provided “welcome pro-business proposals such as the treatment of R&D tax credits for smaller companies and a long overdue review of the business rating system.” Elsewhere, the organisation set its sights on the challenge of avoiding a skills shortage in the industry through its annual conference held in March. CEA chief executive Rob Oliver said its Sector Study showed that most companies had recruitment and skills issues. The conference therefore addressed the issue from both the supply side (the education pipeline of potential recruits) and the demand side – where the skills gaps are – and what businesses can do about it. Other areas looked at included upskilling, and opportunities for outsourcing. “We aim to provide enough information and ideas to give businesses a tool kit for bridging the skills gap,” remarked Mr Oliver.

In one of the most important discussions, Professor Simon Hodgson, President of the Engineering Professors’ Council and Dean of the School of Science and Engineering at Teesside University, delivered the keynote speech exploring firstly the issue of quantity. How can the pace of the sector’s growth be married to the skill levels it has at its disposal without impacting upon quality? He also discussed how the industry can ensure that those individuals being produced by the higher education system also have the skillsets and attributes that are needed by employers, both for the immediate and longer term. Now that the new government has established itself at No. 10 post-election, the CEA will move to step up its bid to lobby for beneficial change and push for policies revealed in March’s budget to be implemented. “Extra support to encourage exports to China is an interesting initiative” of the budget, said Mr Oliver in March. He added: “The policy battle for our sector will be post-election when commitments to medium to long term infrastructure spending will come up against the pressures of political expediency.” If you would like to become a member of the CEA please complete the CEA membership application form and return this to cea@admin.co.uk. Your application will then be acknowledged by the membership department. Please note that all applications for membership are subject to approval by the CEA Management Council. www.thecea.org.uk

EQUIPPED TO MATTER

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CIVIL ENGINEERING RED RHINO CRUSHERS

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CIVIL ENGINEERING RED RHINO CRUSHERS

WORLDWIDE PRESENCE From its established base in the UK, Red Rhino Crushers enjoys an enviable reputation within the crushing sector, providing performance, reliability and value for money.

Perhaps a sign that the UK economy’s outlook is brightening or perhaps further indication of the country’s manufacturing prowess but Red Rhino Crushers’ significant success in the last few years highlights a more specific quality: an ability to consistently deliver the right solutions for its clients. From its established base in the UK, operating from headquarters in Grantham, the business enjoys an enviable reputation within the crushing sector, providing performance, reliability and value for money. Its brand is recognised as an industry leader, the qualities of which have allowed it to grow its international presence. Over the last couple of years it has moved to develop its manufacturing processes with the opening of a new state of the art production facility, while investment in the workforce has brought in key skills and experience to aid its growth both in the UK and abroad. This has coincided with continued product development with new equipment such as the Grizzly Feeder 7000+ crusher becoming its most popular product in 2015. The machine, which was designed as a solution to growing demand for a vibrating feeder with grizzly bars, is the ideal crusher for waste transfer stations, skip companies and plant hire businesses which have limited space. Its capability includes the crushing of concrete, kerbstone, marble, paving slabs, bricks, tiles, blocks, stone, porcelain, flint, gravestones and more with an output of 45 tonnes per hour achieved in optimum conditions.

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CIVIL ENGINEERING RED RHINO CRUSHERS

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CIVIL ENGINEERING RED RHINO CRUSHERS

One of the features of the 7000+ is the capability to provide side loading from a Bobcat, a key requirement for Red Rhino’s American customers. This is in addition to optional extras such as a magnet conveyor to remove rebar and both a motorised and nonmotorised screener. It’s important to be adaptable to client needs, says sales consultant Andrew Dakin, particularly when you’re trying to establish a foothold in new, international markets. Two recent additions have addressed the need for mini screeners and crushers. Firstly, a screener capable of dealing with 80 tonnes per hour and secondly an impact crusher designed specifically but not exclusively for the glass recycling industries. These machines can greatly benefit a project’s financial and environmental efficiency. It is estimated around two billion tonnes of waste is generated in the EU alone each year with a third coming from construction and demolition. Implementing onsite recycling

our machines with the sort of full support and service that meets our exacting standards in the UK.” Andrew has spent the last few months analysing the international marketplace in order to identify potential growth areas for Red Rhino. Priority has been assigned to those territories that meet relevant criteria such as ease of entry, import duty and native language in order to develop new partnerships with distributors of Red Rhino products. Progress has been particularly good in the USA. “The United States was an obvious target because, quite simply, it is the country with the largest GDP. However, in addition, the economy is very buoyant, there are no language barriers, entry is relatively straightforward and there’s no duty from the UK for our products while shipping costs remain cheap. It takes a while to get established in new markets but we are very confident in our product and our progress in America has really developed strongly in the last couple of years,” remarks Andrew. Sales in the UK are mainly handled directly (with an additional dealer in the north of England) with servicing and after-care carried out from Red Rhino’s site in Grantham. However, as a “local” presence is so important, training is offered for its international does not only save significant amounts of money but in the long term also reduces overall carbon footprints through a significant reduction in vehicle movements. Confidence to spread its wings across an international platform is now a key agenda for Red Rhino. “We do have quite a lot of representation around the world but generally speaking that is with small distributors,” says Andrew Dakin. “We want to up the ante and go to companies that are better funded, better organised, and able to stock and rent

“What really makes us stand out is that we’re a family run, British engineering company that manufactures the products here in Grantham” partners so the same attentive level of service can be provided wherever a customer may be in the world. Red Rhino’s potential for growth has been made possible thanks to a number of factors but Andrew feels perhaps the most important is “family”. He says, “What really makes us stand out is that we’re a family run, British engineering company that manufactures the products here in Grantham. That’s why we can constantly meet the needs of our clients and ultimately complement their operations.”

www.redrhinocrushers.com Tel: 01476 590790

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innovation

ACADEMIA INNOVATION IN EDUCATION

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in education

ACADEMIA INNOVATION IN EDUCATION

University research is becoming a large part in the development of modern day technologies. With the constant demand for technology to be bigger and better, University research centres are in high demand to bring out the latest findings in technological advancements. A lot more interest is now being shown in University research programmes as they can be very beneficial not only to companies but the students and professors that take part in the projects. Millions of pounds are put into University research each year and some interesting discoveries have already been made. At Oxford University, the UK’s top Uni for research (according to a recent study by the University Research Excellence Framework 2014), progress has been made in the field of Social Sciences. Longstanding research has shown that increasing levels of Omega-3 in a child’s diet can help those who suffer with Attention Deficit Hyperactivity Disorder (ADHD) by improving their concentration and learning ability.

A study was conducted with two groups of children, all of which had reading ability test scores in the bottom third of the national average. One group received an Omega-3 DHA supplement and the other received a placebo, they each took one supplement a day for 16 weeks. The study concluded that the children who were given the Omega-3 DHA supplement performed distinctively better in the reading and behaviour tests after the course of Omega-3 DHA. Professor Paul Montgomery at the Centre for Evidence Based Intervention wondered if this fact can be said for children without ADHD or without a specific medical condition. He said: “DHA supplementation appears to offer a safe and effective way to improve reading and behaviour in healthy but under-performing children.” Meanwhile at the University of Bristol Professor Paul Weaver and colleagues have contributed towards the creation of quieter propeller blades that could provide smoother rides for helicopter users. Helicopters are known to make a lot of noise when flying overhead and it’s

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ACADEMIA INNOVATION IN EDUCATION

“The collection of robots uniquely includes an industrial robot arm running on a five-metre rail”

pretty hard to miss one when they do. Helicopter makers AgustaWestland approached the team at Bristol University when creating new blades for their EH101 helicopters, also known as Merlins. When developing the blades with PhD student Stuart Lemanski, Prof Montgomery had to take into account several concepts of structural engineering such as; the “twisting” motion that could occur with the blades if a novel composite direction was used for both top and bottom blades and also how to reduce the vibratory forcing that the old blades were giving off. “The benefits to AgustaWestland have been substantial. The new blades could be fitted to the EH101 with the rotor hubs and airframes now experiencing no extra vibratory forcing.” The benefit of the newly designed blades has been considerable and will benefit many people. Many different topics are been explored at Universities all over the country. For example, at the University of Westminster research is currently been undertaken in the field of Architecture. Something that will benefit the research being done there is the opening of a brand new cutting-edge

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Fabrication Laboratory called ‘Fabrication Laboratory Westminster’, located on the Marylebone campus the lab contains brand new state of the art equipment including, ABS and plaster 3D printing, CNC knife cutting and large scale CNC routing. “The collection of robots uniquely includes an industrial robot arm running on a fivemetre rail across a window visible from Marylebone Road.” Opened in April 2015 these new facilities will give students the opportunity to better their studies by having access to the best equipment possible. The lab will provide students with the perfect surroundings to further their knowledge about 21st century digital fabrication. Dr David Scott, Senior Lecturer and academic leader for the Fabrication Laboratory Westminster, said: “The new Fabrication Laboratory will allow students to immerse themselves in and explore the exciting and rapidly expanding field of digital fabrication. It gives them a fantastic opportunity to produce work of the highest quality, offering new design possibilities and creative outcomes.” The University of Salford has been doing research into

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ACADEMIA INNOVATION IN EDUCATION

Biomedical Science, research on topics such as children’s cancer, Parasitology and the function of cells/organs in the human body and animal systems in physiological and pathological settings is currently been undertaken at the University. The Biomedical Research Centre (BRC) has been working with Kidscan Centre for Children’s Cancer Research which looks into new and improved ways to treat children diagnosed with cancer. “Active research programmes also include immunological aspects of cancer and infection, tissue and inflammatory response to damage and disease and applications of biotechnology.” Kidscan’s main aims are to: “Cure children with cancer, to improve the treatment of children with cancer, to develop new treatments and

support programmes specifically for children suffering with cancer and to be a source of information about childhood cancer.” The partnership with BRC will help speed up the process of meeting those aims and with the help of the University researchers we could be one step closer to the answer we need. Another major research topic at the University it Parasitology which includes looking into: “Aspects of pathology, drug action and diagnostics for malaria, trypanosomiasis and larval cestode infections with implications for both human and animal health.” All research been undertaken has an end goal to benefit the human race and also animals. With the development of partnerships between organisations, companies and University research programmes we step closer to getting the answers to the toughest medical and technological questions and a step closer to solutions of the toughest problems.

“we step closer to getting the answers to the toughest medical and technological questions and a step closer to solutions of the toughest problems” MANUFACTURING AND ENGINEERING MAGAZINE

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THE LAST WORD...

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Emerging underwater technology is allowing us to discover new things about the ocean every year

goal, such as surveying an underwater environment and feeding back information. Another recent development in the world of AUV’s is project Icefin. Icefin is a Remotely Operated Vehicle (ROV) which has brought back never seen before footage of Antarctica’s Ross Ice Shelf. Researchers say Icefin is ‘Capable of diving 0.9m (1.5 kilometres) below sea level and conducting 1.9 mile long (3 km) surveys’. On its most recent expedition Icefin was dropped down a 66 foot deep hole in the Antarctic ice which measured 12 inches in diameter, it then managed to dive a further 1,640 feet (500m) to reach the sea floor and bring back surprising footage of underwater life at such depths. This depth is an outstanding achievement as other ROV’s in Icefin’s class have only ever been able to reach depths of a few hundred metres. This project aims to help us understand how Antarctica’s ice shelves are changing under warming global conditions.

exploring the ocean

Substantial developments are being made in the world of underwater robotics. Projects such as CoCoRo and Icefin are testing the boundaries and capabilities of using technology underwater. Collective Cognitive Robots (CoCoRo) is a collaboration project between several European Universities which aims to create a swarm of Autonomous Underwater Vehicles (AUV’s) that can interact with each other. Some of CoCoRo’s main aims are, “Generating swarm-level cognition within such an underwater swarm, comparing the achieved level of global cognition to biological reference organisms’ and ‘Developing novel autonomic systems capable of swarm-level self-identification.” CoCoRo aims to conduct sophisticated experiments into cognitive swarm systems and delve deeper into the world of swarm intelligence as well as the depths of the ocean. The swarm of robots consists of 41 small AUV’s which communicate with each other and work together to achieve a larger

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ISSUE 418

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INSTITUTE OF EXPLOSIVE ENGINEERS promoting the occupational competency, education and professional standing of those who work with explosives

RED RHINO CRUSHERS Performance, reliability and value for money P60

SHARING IN GROWTH

ISSUE 418

Developing highly valued manufacturing for this generation and the next... P42

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