Manufacturing Today Europe Issue 132 September 2016

BEST PRACTICES FOR INDUSTRY LEADERS

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Get yourself

connected The Internet of Things (IoT) is being hailed as the next industrial revolution. But how realistic are these pronouncements?

Also in this issue:

International expansion • Customer service Enterprise Resource Planning • Rust prevention

EUROPE

132 September 2016

MANUFACTURING

Editor’s Comment

Chairman Andrew Schofield

Art Editor/Design David Howard Staff Writers Jo Cooper Andrew Dann Joshua Younespour

The new hot

topic

Production Manager Fleur Daniels Production studio@schofieldpublishing.co.uk

T

Advertising Administrator Tracy Chynoweth studio@schofieldpublishing.co.uk

o me The Internet of Things feels like the new ERP. Not the technology of course, but the amount of discussion about it – every day I get new information on that topic, just like I used to on ERP! I also remember MRP but nowadays I rarely hear of it – let me know if that’s still an area of discussion or an acronym that has gone by the wayside.

I’ve got both IoT and ERP in this issue – maybe I was feeling nostalgic when I organised the content (and I did think back to the old days of ERP when we were all talking about massive ‘big bang’ implementations and whether to go for best of breed or not.)

I am sure that ERP did transform some supply chains and some organisations – and undoubtedly IoT has the potential do the same. I wonder what three letters we will be discussing in another ten years time?

Operations Director Philip Monument Editorial Researchers Mark Cowles Tarj D’Silva Alasdair Gamble Jeff Goldenberg Natalie Griffiths Kya Johnson Ben Richell Richard Saunders Kieran Shukri Laura Thompson Advertising Sales Joe Woolsgrove - Sales Director Mark Cawston Tim Eakins Andy Ellis Darren Jolliffe Jonas Junca Dave King Theresa McDonald

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Editor Libbie Hammond

Get yourself

connected The Internet of Things (IoT) is being hailed as the next industrial revolution. But how realistic are these pronouncements?

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Also in this issue:

)NTERNATIONAL EXPANSION s #USTOMER SERVICE %NTERPRISE 2ESOURCE 0LANNING s 2UST PREVENTION

©2016 Schofield Publishing Ltd Please note: The opinions expressed by contributors and adver tisers within this publication do not necessarily coincide with those of the editor and publisher. Every reasonable effor t is made to ensure that the information published is accurate, and correct at time of writing, but no legal responsibility for loss occasioned by the use of such information can be accepted by the publisher. All rights reserved. The contents of the magazine are strictly copyright, the proper ty of Schofield Publishing, and may not be copied, stored in a retrieval system, or reproduced without the prior written permission of the publisher.

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Features 4 News

Updates and announcements from the manufacturing arena

6 International exports

If you want to maximise international trade opportunities, having access to the right language translation service could be pivotal

10 ERP

There are multiple factors to consider when investing in an ERP system – Jack Payne takes a look at how to identify what’s important

6 International exports

12 Rust removal 12 Rust removal

The global cost of rust is claimed to be $2.2 trillion a year and the Pentagon calls it ‘the pervasive menace’. How can it be tackled?

14 Internet of Things

8 Customer service

The most effective customer centricity often calls for a quiet revolution – but this process will start with the right data

14 Internet of Things

Will the Internet of Things be the saviour of manufacturing in the UK? Nayaki Nayyar takes a look

8 Customer service 2 www.manufacturing-today-europe.com

CONTENTS

Profiles

17 UK Steel

17 UK Steel 23 Silentnight Group 28 Automotive Insulations Ltd 30 TOS Varnsdorf a.s 32 M Squared Lasers 35 Munck Cranes AS 38 Tele-Fonika Kable 45 RS Motorhomes 48 Summitglow Ltd 51 AR Metallizing NV 54 Hoshizaki Europe Limited 56 Anstey Wallpaper Company Ltd 59 Sukhoi Civil Aircraft Company (SCAC) 64 Bristow Group

30 TOS Varnsdorf a.s

67 The Sertec Group Ltd 72 Servopresse Srl 74 Collins and Hayes Furniture Limited 77 Broadwater Mouldings Ltd 80 Mecaplast Group 84 Sumgait Technologies Park 86 Ronaldsway Aircraft Company Limited 89 James Dewhurst 92 Widex

56 Anstey Wallpaper Company Ltd

94 Enesco 92 Widex 74 Collins and Hayes Furniture Limited

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News in brief New IoT data study

Xively by LogMeIn, Inc. has released the findings of a study conducted by Forrester Consulting on behalf of LogMeIn (Simplifying the Complexity of IoT) that reveals product companies may be missing a huge opportunity when it comes to their Internet connected products. The research found that while many companies (51%) are collecting data from their connected products, only about one-third are actually using this data to create actionable insights to benefit customers and expand business opportunities. In addition, the survey revealed a number of other challenges facing product manufacturers today, including data security.

Margin management

Based on conversations with C-level executives, and by analysing the results of a survey of 200 CFOs and CMOs, a new in-depth report by Vendavo and Cranfield School of Management reveals that those who report growth ahead of market expectations are more likely to say that maintaining or increasing margin is vitally important (41%) to their organisation, in comparison to those behind (4%). Despite striking evidence that a lack of insight into margin is damaging shareholder value and the financial health of organisations, more than a third (38%) would not know how to affect an increase in margin tomorrow.

To help organisations take positive steps, this report offers an Eight Actions model outlining how to regain control of margins at the practical level to beat market expectations.

Procuring skills

Research from Robert Walters has found that half of employers believe they will face skills shortages when looking to recruit procurement and supply chain professionals this year and 20% believe that Britain’s decision to leave the EU will exacerbate the skills shortage. Mid-level professionals are likely to see the highest demand for their skills, with 76% of employers planning to recruit procurement and supply chain professionals at this level. James Franklin, Manager, Procurement & Supply Chain Recruitment, Robert Walters, comments: “Improving inefficient procurement functions has been a key focus for many businesses as they realise that changes made can significantly reduce costs. This has led to a rising demand for specialists in this field.”

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Automation and application

JBT has redesigned its range of Automatic Guided Vehicle systems (AGVs) into standard modules, which can be combined to suit different applications, with the aim of simplifying AGV solutions and the way customers make purchases.

This redesign means that JBT can quickly deliver a broad range of high value, low cost AGV solutions, where each application is matched with the appropriate level of automation. The modules include load handling, battery, controls, rear support and power (for either hydraulic or electric vehicles).

“Each of the modules has been cost-reduced and optimised,” explains Mark Stevenson, JBT director of sales for Europe. “In doing so, we’ve also increased the reliability of the modules as each one has proven its effectiveness, so the vehicles don’t need to be custom-designed for each project.”

JBT used its experience and leveraged patterns in AGV sales while implementing its redesign. In addition to the vehicle redesign, the company also updated its SGV Manager software by introducing a 3D mapping system to maximise system throughput.

“We wanted to take away the complexity and mystery from AGV systems,” adds Mark. “The 3D map provides a real-time, virtual view of the AGVs at work, and allows users to pan or zoom the view to easily monitor and optimise the system.

“The software also allows users to easily navigate to other screens so, even if they only have a little training and experience, they can quickly interface with the system.”

Merger reflects change

The recently announced merger between the Chartered Institute of Logistics and Transport (CILT) and the Institute of Operations Management (IOM) reflects rapid changes to roles in the supply chain, especially post-Brexit, according to recruitment specialist Jonathan Lee Recruitment.

Mark Bignell, supply chain expert explains: “This collaboration mirrors big changes we are seeing in the types of skill sets being demanded of supply chain professionals. It is a further demonstration of how commercial and technology drivers are evolving the supply chain, particularly in relation to the potential for it to deliver positive business transformation and improve performance.

“It is great to see the recognition that successful supply chains are vital to commercial success and the increasing value that is being put on the individuals who can drive that growth.

“Despite the current uncertainty around Brexit, now more than ever we must nurture the people who have that rare combination of skills. As we look to reconfigure our relationships with Europe and the world, supply chain experts with commercial savvy will be key to delivering the opportunities and minimising business risks in such a period of transformation.”

Jonathan Lee Recruitment has seen an increased focus on how roles are becoming more demanding and more diverse across logistics, materials planning, purchasing and commercial roles in manufacturing. There has been a marked growth in securing the supply chain leaders with strong business transformation skills that can support the rapid changes in manufacturing business as they deal with changes post Brexit.

MANUFACTURING NEWS New limits

METTLER TOLEDO has launched its new XPR balance line. Offering both micro and ultra-micro models, XPR offers a welcome combination of usability, accuracy that is critical in industries such as pharma where sample sizes are small and productivity must be maintained.

Notable in the new line is XPR6UD5, the first ultra-micro balance on the market. It offers 0.5µl resolution at 25 per cent better repeatability than traditional microbalances using a blend of innovative design characteristics, including: heightened stability via Active Temperature Controlling (ATCTM), which draws heat away from the balance for enhanced measurement accuracy and repeatability, ongoing quality assurance through GWP Approved, which automatically checks tests, adjustments, levelling, and settings prior to weighing, and user profile storage with Tolerance Profiles, which ensures that weighing tasks meet defined process requirements and applicable regulations.

Usability is delivered by a small bench print and new user interface that, similar to a smartphone, allows users to swipe on programming and running tasks. A built-in result notepad simplifies documentation and lets users to store comments. Individual task methods can be stored and accessed via icons, saving time and enhancing process security.

Additional XPR design benefits include a new weighing pan for easier cleaning and USB data transfer for quick export of task parameters or results. A two-screen system allows the main touchscreen to be placed wherever it is more ergonomic and convenient.

Taken together, XPR’s productivity-enhancing features and repeatable micro-range accuracy allow it to create a new level of productivity for companies working with small sample sizes.

Going paperless

44

Siemens is launching Version 6.1 of its Simatic IT eBR software, which is at the heart of its Manufacturing Operation Management for the life science industries. The new version of the software enables users to easily implement paperless manufacturing solutions by offering two main features: A new web-based MBR (Master Batch Record) module which facilitates the management of key process parameters, and native integration with the Siemens automation layer (Simatic PCS 7 process control system and HMI systems).

With its new Master Batch Record module and a ‘Project Startup’ package, Simatic IT eBR 6.1 provides a list of out-of-the-box deliverables to speed up project execution time. In addition, it offers native integration with Siemens PCS 7 Batch and new access to electronic work instruction lists embedded in SCADA/HMI clients. By accelerating the design, execution, review and release of regulated production processes and electronic batch records (EBRs), Simatic IT eBR helps both enhance product quality and lower production costs.

Branding refresh After 15 years continuous growth, manufacturing software specialist Forcam has completed a comprehensive re-brand. With a directly employed staff of over 150 at its German HQ and subsidiaries in the UK, USA, China and Poland, the company has over 160 user locations and provides data streaming connectivity for over 60,000 machine tools and processes, enabling manufacturers to significantly boost productivity.

UK managing director, Andrew Steele explained: “We work globally with major international companies such as Daimler, Audi, BorgWarner, GKN Aerospace and Weir Minerals, so the time was right to modernise the company presentation. In addition to new branding symbols, we have a new web site, brochure and a programme to provide more information for current and prospective clients. Improving competitiveness through better productivity is a major business driver in the UK. Our message is that we can deliver first year gains of around 20 per cent or better for most clients and provide them with a system they can use for continuous improvement of their processes.”

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Clear

communication

Language skills – the key to maximising international trade opportunities. By Geoffrey Bowden

I

n the wake of the UK’s decision to leave the EU, questions are already being asked about the impact not just for the UK, but for their key European trading partners too. As yet, many of the answers remain unknown and as we enter what will inevitably be a period of significant change for the industry, we discuss the role, which language services can play in supporting this vital sector.

The short-term post referendum picture appears to be one of opposing fortunes for the European manufacturing sector, with the fluctuation in exchange rates impacting on export levels from both within and outside the UK. Indeed, while a falling Pound may start to make British manufactured goods look more competitive, the reverse could be said for the products of

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manufacturers from other European countries who have to date exported high quantities to the UK. Downward forecasts are already being made on exports to the UK from bodies such as the German DIHK Chamber of Commerce and Industry for example.

Longer term, the impact of potential tariffs alongside predictions that a Brexit may result in regulatory divergence, thus increasing trade costs and damaging bilateral trade volumes, have been widely discussed for many months. Despite this, the result of the EU referendum was still largely unexpected and shockwaves are continuing to be felt across Europe, with the uncertain future of European exports remaining a hot topic.

This uncertainty only compounds the already high pressure on the

International exports

manufacturing sector, which accounts for more than two thirds of EU exports and 15 per cent of European GDP, to become more competitive to help restore economic growth across Europe. The challenge then is for the European manufacturing sector to wrestle back control of its own destiny and take proactive steps to ensure its future success. Effective use of language services will form a key component in answering that challenge and the importance of accessing the appropriate foreign language skills for targeting overseas markets should not be underestimated.

Language is vital for effective communication with international trading partners and if used effectively can positively influence export performance, with recent research indicating that poor language skills are costing the UK economy alone £48 billion a year in lost export sales* and conversely, organisations which have made the conscious decision to invest in language services achieve a far higher export to turnover ratio**.

But it isn’t simply about translating materials into the native language of existing and prospective clients, it’s a much more powerful tool which enables manufacturing companies to build positive long-term relationships, understand cultural differences, adapt how they do business and market their products effectively to suit local markets. In the words of the legendary Nelson Mandela: “If you talk to a man in a language he understands, that goes to his head. If you talk to him in his language, that goes to his heart.”

It was therefore concerning in a recent survey*** of Europe’s Language Service Providers (LSPs) that while there were overriding predictions for growth across the sector during 2016, these were at a much lower level than in 2015 and in some countries, such as Italy, there were even predictions of contraction in the industry.

Rather than viewing language services as a cost and perceiving the language barrier as too large to overcome, manufacturing organisations regardless of size and location need to sit up and recognise the role which Language Service Providers (LSPs) can play in supporting them to become effective exporters. They wouldn’t, for example, hesitate to invest in other professional services, such as legal and financial, and it is important that the value of language services be viewed on equal terms.

Indeed, accurate translations, in which all colloquialisms and cultural references are correct, can add great value to a business, helping them communicate effectively in diverse markets and therefore expand their opportunities for international trade. This is key not only for the traditional and well established manufacturing markets of Western Europe but also for the rapidly emerging and fastest growing markets of Central and Eastern Europe. Plus, with manufacturers increasingly selling services in addition to manufactured products; the ability to communicate effectively with customers across multiple territories appears more crucial than ever.

However, it is only by accessing the right services from the right professional language company that this opportunity can be fully maximised and unfortunately many organisations are still failing to take into account the need to plan ahead for their translation requirements, with few knowing what to expect when trying to source translations from an external provider.

To help manufacturing organisations maximise their international trading potential, a Guide to Buying Language services has therefore been made available by the Association of Translation Companies for all European manufacturers to download (http://bit.ly/29tq2G1). Designed to help any company investing in translation services, potentially for the first time, to get the very best results for their money, the guide provides advice on everything from how to select an LSP to the different services available, best practice when it comes to briefing a translation company, the pros and cons of digital translation and even some language industry jargon, of which clients should be aware. v

Geoffrey Bowden Geoffrey Bowden is General Secretary of Britain’s Association of Translation Companies (ATC). ATC is the world’s longest established professional association representing the interests of Language Service Providers. It is the leading voice for companies operating in the UK’s expanding language services industry, which is worth more than £1 billion and employs more than 12,000 people. www.atc.org.uk

Sources: * Department of Business, Innovation and Skills ** Volume 62, Issue 4 of the Scottish Journal of Political Economics, autumn 2015 *** Joint survey conducted by the European Union of Associations of Translation Companies (EUATC), the Globalization and Localization Association (GALA), the European Commission and the European Language Industry Association (ELIA).

In focus:

One European manufacturer that is already reaping the benefits of accessing professional language services is Proto Labs. Founded in 1999, Proto Labs has grown into a global manufacturer with production facilities in the United States, Europe and Japan. Over the past decade it has commissioned the services of LSP, Alexika, a member of the UK’s Association of Translation Companies, which has delivered translations for key trading markets including Germany, France, Italy, and Spain and more recently Sweden and Finland.

With the rapid growth in its 3D printing, Computer Numerical Control machining and injection moulding services providing an unprecedented speed-to-market for Proto Labs customers, it sought the support of an LSP which could deliver a flexible, accurate and efficient service.

Ashlea Babb, Marketing Project Coordinator Europe explains: “It is important for us as a global manufacturer with an international customer base to provide appropriate levels of support. One part of this is language service support. Alexika translates content including print, technical and digital marketing materials, successfully helping to promote our services to customers in different European territories.

“We evaluated the services of Alexika with those of other providers, both within the UK and Europe and chose to retain their services over the last ten years. We have a primary tier of translation experts who understand our business, the pressures that we face and the need for accuracy in the technical market place in which we operate.

“Our key objective was to find an agency willing to become a long term partner, committed to learning our business and evolving to meet its needs. To date Alexika has delivered on all these objectives, continuing to offer excellent service levels and we value the support which they provide.”

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Collaboration

at its best Ian McVey explains why customer centricity is synergy, not science

Top down leadership has its merits, but so does an empowered, involved workplace that listens and reacts to its opinionated and socially active customer base

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I

n discussion with the founder and CEO of a well-known FTSE 250 furniture manufacturer, I asked where he sources the inspiration for his designs. ‘The bottom line’ he replied, going on to stress the importance of feedback from his trade customers and showroom staff, shifts in technology and materials. Mostly it came down to personal intuition, so I asked how often he makes mistakes; ‘Hardly ever’ he replied.

But then so would I. This was not the man to engage in the minutiae of multi channel marketing or customer journey mapping. His was a personal approach to insight rather than a scientific one, though I suspect he knew better than totally to ignore opinions that defied his intuition.

What connects this self made man to the wider corporate world, to the inspired tech visionary and the suited FTSE CEO, is that at one point or another they have all failed. Some got away with it, others paid the price. Each has to decide when to follow the herd and play it safe, or to defy conventional wisdom and strike out. Each makes decisions in ways few let on.

The problem with such guarded decision making is that while it plays to a stereotype behind the cult of the CEO, it is neither informed nor informing. It fails to include valuable opinions from employees and customers at a time when both parties have never been keener to share them, or been more proficient at doing so. In an interrogative world it can be seen to be fallible too.

Customer service

Top down leadership has its merits, but so does an empowered, involved workplace that listens and reacts to its opinionated and socially active customer base.

Need the two collide? Do the benefits of widely sourced reasoning and objective insight outweigh the strength of subjective intuition? How do we strike the balance between inclusive and instinctive leadership? For clues, we might turn to our political masters where on the one hand Jeremy Corbyn has democratised Prime Ministers Question Time by inviting members of the public to ask the questions, and on the other Theresa May has announced her intention to put both employees and customers on corporate boards.

In politics and in commerce, inclusive insight should never substitute intuition, it should challenge it, not just at the Despatch Box or in the CEO’s office, but right across the enterprise, from operations to production, finance to supply, technology to HR, and especially in the call centre, where customer facing staff are unadorned ambassadors.

That’s why the most effective customer centricity often calls for a quiet revolution – the replacement of business as usual with fresh perspective, imagination and often a change in culture. In China, robots on the factory floor are being integrated with real time data from customers. In our search for new markets and innovations post Brexit, against a background of competitive disruption and customer disloyalty, new thinking has never been more important.

No one said it was easy. If customer centricity was simple to achieve, it would have been patented by now.

It all starts with data. Customers will come if you build the right product, but you cannot build it without knowing what customers want. Data, however, can be a most deceptive mistress. Data can be ill disciplined. Where is the feedback you collect from your customers fed back into? Across the business? To intelligent people who know how to collate, extrapolate and share it? Or to the same algorithm that asked the question in the first place.

Data can be deceptive. The more data you harvest, the sharper the outcome should be, but the greater its volume, the less context it contains and the more questions it begs. A manager might know that 75 per cent of prospects are turning down a finance agreement, without realising

that the reason lays in confused wording on the application form. Customer facing teams might be pushing out technology in the form of questionnaires, proper procedures might be followed, but the organisation is none the wiser and the customers’ voice is unheard and ignored, which risks making them feel taken for granted.

Perhaps the most puzzling data problem is management’s failure to realise its potential as a ‘pull’ factor in customer engagement. In the digitised age, we are good at pushing out technology, but not always as good at pulling in valuable insight, freely given by customers who actively want to share their thoughts. Without it, go to market investment decisions are unsupported by solid customer research.

The technology to ‘pull’ the data, however, has evolved dramatically in a short time. Gone are the days of a static annual survey. Insight is now continuous, with regular ‘pulse’ surveys that report in real time. These depend on agile, modular software that integrates with existing systems, with no need to rip, replace or upgrade hardware.

Questionnaires encourage engagement, not abstention, and the software feeds results quickly to all those who need to be ‘in the know’.

Management profits from access to simple to use dashboards on which real time data keeps track at every stage of the customers’ journey.

Data scientists draw insights, discovering gems of information they simply did not have. In sectors built on silos, where a unified view of the customer is often lacking, modern software overcomes the dangers of disparate systems that have never collated data centrally. If something goes wrong, responsibility is assigned and progress is checked. If a new product needs to be proven, the metrics with which to do are in place.

Changes in process soon bring shifts in the balance of power within and without the enterprise, as employees, (associates), are aligned with customers, (partners), guesswork is relegated to the past and decisions are reached transparently in the full light of insight.

Taken from the Ancient Greek, ‘Synergy’ is defined as ‘working together’; the ability of a group to outperform even its best individual member.

Customer centricity is collaboration at its best.

Applied scientifically across a modern enterprise, it has the power to align management, drive corporate strategy and ensure mistakes are no longer ‘hardly ever’ made, but not made at all. v

Ian McVey Ian McVey is UK Director, Qualtrics, a specialist in customer and employee engagement. Qualtrics is a rapidly growing software-as-a-service company and the provider of the world’s leading enterprise insight platform. More than 8500 enterprises worldwide, including half of the Fortune 100 and 99 of the top 100 business schools rely on Qualtrics technology. Its solutions make it fast and easy to capture employee, customer, and market insights in one place. www.qualtrics.com

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The cost of

Jack Payne takes a look at what makes the most sense for your business

While having access to the trendiest features and functionality of an ERP solution sounds like the most obvious reason to invest, sometimes that doesn’t always make the most sense. It is up to each individual business to analyse the costs of purchase and implementation and compare it with the net annual benefits to calculate their ERP pay back opportunity

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W

hen beginning your quest to purchase an ERP solution, building a case for the cost benefit should be priority. However, focusing on all of the bells and whistles of a new ERP often overshadows looking at an actual cost benefit and understanding the overall value you are getting with your ERP. ERP enables you to automate the tasks involved in performing your business processes and gives you insight into all of the aspects of your plant. ERP is an expensive investment but it’s important to understand the cost benefits of a full solution.

ERP COST BENEFIT EXAMPLES AND SUCCESSES Data Collection - the case of the expensive Italian meat

The first week after go live with their ERP, a regular customer ordered their usual type of meat from a well-known Italian meat producer. The user scanned the same meat he had been pulling for years with the data collection application in their new ERP system. The ERP’s data collection system however, failed and would not let him pull the ham. Or did it actually fail? It turned out that the reason the meat wasn’t able to be pulled was because the user had been pulling a higher quality meat at a much higher cost for several years. Thanks to the ERP’s data collection, fixing this one instance alone actually paid for the entire ERP system.

While the instance of the Italian meat may be extreme, cases like this can and will happen. However, there are several other successful ROI opportunities that pay for the cost and help your business benefit from your ERP investment.

ERP what they hope to accomplish with their ERP. However, if a solution that employees cannot actually use is selected, those plans become useless. According to Aberdeen Research Group’s report, How ERP Can Make Your Job Better on a Day to Day Basis, top performers will select a solution that enables users to take advantage of functionality designed to improve their jobs on a day-to-day basis.

The same Aberdeen report states that as compared to all others, leading companies are: l 2.1 times more likely to have an ERP solution that is easily tailored to support business change l 61% more likely to enable users to access reports in a self-service capacity l 2.6 times as likely to have pre-configured dashboards and role-based homepages l 14% more likely to have context-sensitive help and training for ERP l 59% more likely to have the ability to drill down to individual transactions from summaries The bottom line is that the best-in-class invest in an ERP solution that is easy to use. Even the most functional of ERP solutions can end up being a waste of money if employees can’t use it. A user-friendly ERP solution leads to a higher adoption rate among employees and the benefits of the solution will more quickly and profoundly exhibit themselves throughout the entire organisation.

Traceability - don’t let a recall ruin your brand

Food safety is all about prevention – including recall prevention and brand reputation – as well as response. Track and trace technology documents all of a product’s details in its lifecycle, from ingredients to customer shipment. In addition, track and trace solutions can include built-in controls to provide manufacturers with visibility into qualified suppliers and the ability to specify incoming inspection requirements.

It only takes one bad ingredient to force a food and beverage manufacturer into issuing a recall.

Tracing the ingredient fast is the key to minimising consumer risk and protecting a company’s reputation and brand. Without an effective track and trace process, you could easily be the next brand making headlines for unintentionally causing consumer harm, thus losing more money for your business than the cost of an ERP investment itself.

Best-In-Class - set your business up to be the best Overall, organisations need to be using as much of their ERP investment as possible. A Best-InClass organisation may have detailed plans for

Is ERP Worth the Cost?

One of the most common causes of delay in purchasing an ERP solution is trying to figure out which software to use. While having access to the trendiest features and functionality of an ERP solution sounds like the most obvious reason to invest, sometimes that doesn’t always make the most sense. It is up to each individual business to analyse the costs of purchase and implementation and compare it with the net annual benefits to calculate their ERP pay back opportunity.

Finding the functionality that works best for your employees and empowers them to utilise all of the ERP features for better business is what’s going to pay for your system. v

Jack Payne Jack Payne is Vice President of Solution Consulting for Process Manufacturing at Aptean. Aptean is a leading provider of industry-focused mission critical enterprise software solutions. It builds and acquires solutions to support the evolving operational needs of its customers. Its solutions help nearly 5000 organisations stay at the forefront of their industries by satisfying their customers and continuing to operate more efficiently. www.aptean.com/uk

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The hidden

Peter Crossen explains how the manufacturing industry could save its economy from rusting away, using simple rust removal techniques

The total global cost of rust is $2.2 trillion per year, according to George F. Hays, the Director General of the World Corrosion Organization

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D

id you know that rust costs every European country between three and a half and four and a half per cent of GDP (Gross Domestic Product) every year? However, the good news for our economies is that there is a way of repairing the damage to even heavily rusted items. First, allow me to put that three and a half per cent figure in context.

According to the World Bank Group, in 2013 nearly every country in Europe, including Germany, France, the United Kingdom and the Netherlands, spent less than three per cent of GDP on defence. Of the countries for which data is available, seven spent more than four and a half per cent in the same year. This means that, unbelievably, the total cost of rust in every industry is more than the global economy spends on defence!

The total global cost of rust is $2.2 trillion per year, according to George F. Hays, the Director General of the World Corrosion Organization. However, one could argue that the social and symbolic impact of rust is even more far-reaching. It has brought down bridges and buildings, crashed military jets, burnt down houses, rendered nuclear warheads unusable and nearly caused a nuclear reactor meltdown. In fact, it’s so significant to the global economy that author and scientist Jonathan Waldman has recently published an entire book on exactly this subject.

In the book Waldman points out that the Pentagon refers to rust as, ‘the pervasive menace’ and that the United States nearly lost the Statue of Liberty to the damage it can cause. Out of sight but on the surface, rust is a huge hidden cost for industry.

Rust removal

The cost of rust

Both deterioration of components and structures and the weakening of metallic bonds can have a huge impact in industries as diverse as the chemical sector, construction, manufacturing, petroleum, petrochemicals, pulp and paper and transportation, including railroad, the automotive sector and aerospace.

The primary impact is the cost of downtime and loss of productivity as well as the repairs due to rust damage, but there is also the cost of health and safety preparation and compensation.

The manufacturing industry can fall foul of the cost of rust both on the manufacturing line and in storage and transport. In many process industries a high level of acidic chemicals complimented by a ready supply of water can lead to component and tool rust, which can be costly. Furthermore, traceability and validation requirements can often make replacing components expensive and time consuming.

Rust, which consists of hydrated iron (III) oxides Fe2O3·nH2O and iron (III) oxide-hydroxide (FeO(OH), Fe(OH )), creates brittleness in susceptible structures and, given time, will bring a building to its knees.

Even in its mildest forms it can create structural and compliance implications, which can be costly.

As a result, every industry should consider the impact of rust on its buildings as well as its equipment.

When replacing structural work, or component level equipment, businesses should also consider the additional cost of the metal itself. Raw material prices are increasing to the point that most manufacturers will have experienced scrap metal theft at some stage. If scrap materials are

so valuable someone is willing to steal them, consideration should be given to safeguarding the materials that are used in processes.

There is also the impact on the reputation of the business whose property, equipment or goods are rusting. This isn’t a small issue either; and certainly not one for the technical teams to defer to marketing alone. Imagine you are giving a tour of your site to a potential customer and they comment on the rusting equipment stored in the corner, or the structural work covered in the distinctive red-brown markings created by iron oxide. How likely is that prospect to convert into business?

The irony is that, in my experience, we are all blind to rust in our own buildings because it appears so gradually. Each time I tour a facility with a potential customer, I’m invariably able to point out problems they hadn’t noticed, in addition to the specific issue they called me in to deal with.

We can’t eliminate all of the costs or rust, no matter what measures we take to avoid it, but a percentage of that $2.2 trillion could be saved if we take action at an early stage. Even a small slice of such a huge pie could represent a big boost for most countries and, more importantly, for your business.

Rust removal

The answer to the problem of rust removal lies in surveying the application regularly to ensure that any problems or potential problems are counteracted at the earliest possible stage. When an issue is detected, the answer lies in choosing the most appropriate counter measure, provided you haven’t yet gone beyond the point of no return.

If the thing that is suffering from rust can be moved and is small enough to fit into a portable dip tank, then NCH Europe would normally recommend a product called X-Rust 7.

X-Rust 7 removes a light layer of surface rust in 15 minutes, heavy rust in a few hours and severe rust during a twenty-four hour cycle. The product works at room temperature, comes in a cost effective 1:10 dilution, offers a temporary protective coating after use and is pH neutral.

Thanks to the pH neutral composition of X-Rust 7 it is non-corrosive and will not damage other metals, plastic, wood, glass or rubber components that comprise the piece of equipment on which it is used. It also means it is non-etching, safer for users and the environment and represents a time saving option because it doesn’t have to be neutralised before use.

X-Rust 7 is also economical to use and store

NCH Europe has launched X-Rust 7, a powerful pH neutral rust removal solution. X-Rust 7 eliminates even the most severe rust in 24 hours

because of its impressive 1:10 dilution rate and the temporary protective coat it leaves behind prevents flash rusting, buying the user time to apply a protective coating, such as NCH Europe’s Resist X Extra or HyZinc Extra.

Because X-Rust 7 can be used at room temperature, there is no need to bring into play expensive energy to heat the solution or dip tank and no need to have a heat source on site. This also means you don’t have to invest in a specialist heated or heat proof dip tank.

The bottom line is X-Rust 7 is easy to use and the results are clear to see. Most people struggle when they try to come to terms with the scale of a country’s defence budget. Most of us can’t even begin to visualise what the $2.2 trillion that rust costs the global economy every year looks like. However, the real impact on your business is easier to come to terms with; it’s the cost of replacing and maintaining your structures and equipment, it’s the cost of downtime, damage and loss of productivity and it’s the cost of your reputation. v

Peter Crossen Peter Crossen is VP of the Maintenance and Partsmaster Innovation Platform at NCH Europe.

NCH Europe has a presence in 25 countries and a network of over 2,000 sales staff. It cleans and conserves water, saves energy and delivers best-in-class maintenance solutions, with a focus on hospitality, industrial and infrastructure businesses in Europe. www.ncheurope.com

www.manufacturing-today-europe.com 13

Getting to grips with

I

T experts around the world are proclaiming the Internet of Things (IoT) as the next industrial revolution. The list of benefits stretches from predictively fixing problems in the manufacturing process, to enabling manufacturers to enhance product development and respond to customer feedback in real-time, to making massive cost reductions and efficiencies. But how realistic are these pronouncements and what needs to be done to go from prediction to practice?

Gartner believes there will be 25 billion internet-connected devices by 2020 and the manufacturing sector is at the forefront – in 2015 Gartner already measured 307 million installed ‘connected’ units. It also predicted that manufacturing is the sector that will experience most impact, alongside healthcare.

But for the UK’s manufacturing sector there is still a significant gap between expectations of the potential of the IoT and the reality of their investment in it. In a recent study carried out by SAP among leading manufacturing executives almost a fifth (19 per cent) expected no investment in IoT-related technologies in 2016, while the average investment anticipated was just 7.74 per cent of overall IT spend.

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Nayaki Nayyar asks: Will this be the saviour of manufacturing in the UK? This relative lack of investment means that UK manufacturers could miss out. There are certainly pockets of best practice. But just five British companies made Forbes’ list of the World’s Most Innovative Companies, and only one - Arm Holdings, the Cambridge-based chip designer whose technology is used in almost all of the world’s smartphones - made the top five in the publication’s ranking. What then does this say about innovation and investment in new technologies across UK manufacturing, especially when placed against other advanced industrialised economies?

In Germany for example, the IoT revolution has its own name - ‘Industrie 4.0’ - and encompasses a holistic approach to innovation and technology in the manufacturing sector.

The German government is investing 200m euros to spur on research into Industrie 4.0 across government, academia and business. The underlying concept is to connect embedded systems and smart production facilities to generate a digital convergence between industry, business and internal functions and processes.

This isn’t to say that the UK doesn’t realise the significance of the IoT. At the end of 2014 the Government produced its paper ‘The Internet

of Things: making the most of the second digital revolution’ with recommendations to realise David Cameron’s ambition of making the UK ‘the most digital nation in the G8’. In this paper, the Government referred to the ‘transformative development’ that the IoT brings. Now, however, this potential needs investment, dedication and an iron will to drive through change.

The opportunities

The good news is that in SAP’s study of UK manufacturing executives, it’s clear that decision makers recognise the distinct advantages of adopting IoT technologies; over half (51 per cent) saw cost reductions as a major impact. Other benefits noted included an improvement in product development (mentioned by 38 per cent) and improvements in procurement and supply chain management (mentioned by 30 per cent).

One area where these advantages come to bear is in helping improve and exceed expectations in maintenance and repair. Owners, operators and manufacturers of machines often have to manage them at remote sites, limiting their visibility into performance and usage.

Predictive maintenance and service solutions

Internet of Things

allow equipment manufacturers and operators of machinery and assets to monitor them remotely, predict failures, and proactively maintain assets.

They can collect data from remote assets and merge it with business data, such as past maintenance records and contextual data including weather and traffic information. They can then analyse this data to find patterns and root causes for failures - insights that help them predict when an asset or equipment will fail and proactively apply preventive measures to stop the failure from occurring.

An SAP customer, Kaeser Compressors, Inc, uses IoT technologies for just this purpose. The German-based manufacturer of air compressors, wanted to provide excellence of service to its customers across the world. Using IoT platforms and technologies it is now able to collect processing data from air compressors onsite so that it can constantly monitor usage and performance. It can gather a complete picture of a compressed air station and then use predictive analytics to fix problems before they emerge and help avoid unplanned downtime.

The challenges

Of course, as with any new technology, there are barriers to the uptake of IoT platforms. Almost half (47 per cent) of respondents to the recent study of UK manufacturing executives identified a lack of awareness and understanding as the main barrier, followed by outdated legacy technology (mentioned by 43 per cent) and concerns around data protection (mentioned by 42 per cent). Contributing to this fear of the unknown was the lack of on the ground examples of IoT in action – only one in five (20 per cent) have seen an IoT application in practice.

With a lack of awareness and understanding being such a major challenge it is incumbent on the technology industry and IoT experts to do a better job in guiding manufacturers through the journey. If manufacturers can work with IT professionals to draw out the real business value of the IoT, together they can unleash the potential of this new era of technology.

Industry efforts such as Industrial Internet Consortium, which SAP is a member of, aim to do just this. As well as its focus on driving through the adoption of interoperable standards it also plays a role in engaging and supporting end-users in understanding the business benefit and impact of the IoT. Part of this is also about dispelling myths.

Some commentators have voiced concerns that IoT platforms may lead to pressure on jobs.

Encouragingly, in SAP’s recent study a sizable proportion of manufacturing executives saw IoT

technology as a career booster, with almost half (48 per cent) stating IoT innovation will lead to higher value job opportunities.

Changing mindsets is not just about the business benefits but also about showing a pathway for people to opportunities for more creativity and innovation. It’s about highlighting the new job roles that are further up the value chain – whether it’s managing how the IoT can improve manufacturing processes and systems or applying the technology to product and service development. This requires new skills but creates new and exciting opportunities.

Now is the time

This is a genuine pivot point for the UK manufacturing industry. But it requires manufacturers to embrace the new technologies and apply it to their business and commercial challenges. Technologists can wax lyrical about the amazing impact of the IoT, but until people start to explore the opportunities for themselves it will be difficult for them to see the practical advantages. By which time it might be too late.

This requires two things: A mindset shift that is willing to explore new ways of working and to innovate across new technologies. And secondly it requires significant investment. Currently, it would appear that UK manufacturers are holding back from investing in IoT platforms and approaches. But from a practical perspective, now is the time. The cost of entry has never been so low and technology so integrated. This means that even SMEs can think about adopting these groundbreaking technologies.

Moreover, it’s not just about using the technology. More connected and integrated manufacturing systems can move businesses into new markets and create new revenue streams. The IoT could be a boon for the UK manufacturing sector but only if we collectively focus on practical changes in mindset, investment and application. This is the challenge for the technology industry and manufacturers alike. v

Nayaki Nayyar Nayaki Nayyar is GM & Head of IoT Go to Market for SAP. As market leader in enterprise application software, SAP helps companies of all sizes and industries run better. From back office to boardroom, warehouse to storefront, desktop to mobile device – SAP empowers people and organisations to work together more efficiently and use business insight more effectively to stay ahead of the competition.

SAP applications and services enable approximately 310,000 business and public sector customers to operate profitably, adapt continuously, and grow sustainably. www.sap.com

www.manufacturing-today-europe.com 15

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Focus on: UK Steel

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UK Steel

Material to the

economy

Embodying several decades of industry experience, UK Steel provides a central voice to the steel manufacturing sector that offers support to modern challenges ranging from business rates and oversupply to a changing political environment

Photo: Mill Being Heat Treated, taken by Alan Burke, runner-up in the Amateur photographer category of the EEF Photography Awards 2013

W

ith a history that is deeply entwined with the development of the country’s steel production, UK Steel represents the leading trade association and unified voice for the steel industry within the UK and beyond.

Formerly known as the British Independent Steel Producers Association (BISPA), UK Steel has been at the forefront of representing the interests of steel manufactures in the UK during periods of both national and private ownership and today continues to champion the sector. During 2001 the BISPA changed its name to UK Steel before finally undertaking a major restructuring and merging with EEF, the leading trade association for manufacturing in both the UK and European Union, to become a stand-alone division within the federation. EEF was founded in 1896 as the Engineering Employers’ Federation and later merged with the National Employers’ Federation in 1918. In November 2003 EEF rebranded itself as EEF - the Manufacturers’ Organisation and currently incorporates thousands of members, comprising manufacturers of all sizes across the UK. EEF is the leading voice of UK manufacturing and engineering that also provides a comprehensive source of business support. It

is the aim of EEF to aide businesses operating within the manufacturing sector to continue to be able to thrive, innovate and compete both locally and on a global scale. The organisation works with a wide range of individuals ranging from industry leaders, managers and professionals to young people apprentices, policy-makers and media representatives, which enables it to promote and support enterprise within the UK, while making sure businesses remain future-focused and competitive. As an independent division within EEF, UK Steel shares the goals of the wider organisation and provides its members with a central point of contact and specialised support.

Membership of UK Steel is open to all UK-based companies involved in the production of steel as well as to the associated down stream processes including rolling, drawing, coating and tube making.

“Our membership is made up of almost the entire UK steel sector, which includes all of the steel making companies operating within the UK and most of the downstream activities within the market. We are here to represent that sector as a whole, to liaise with the Government to provide further services and support to the steel industry, as well as to work with our members to develop best practice guides and innovations relating to health and safety and technical considerations,”

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Wrexham Wire With over 40 years’ experience in manufacturing high quality drawn steel wire Wrexham Wire now bring automotive industry levels of customer service, product quality and process efficiencies to the drawn wire industry.

An influx of high-calibre, professional senior management, new owners and the long-standing technical expertise of the incumbent team defines the customer centric approach of the UK’s premier drawn wire solution provider.

Significant capital investment in the high-carbon (bedding and seating) and low-carbon (cold heading) processes continues to add capacity, increase range and enhance efficiencies. Modern defined capacity production planning systems support the drive to achieve world-class OTIF performance.

Located on the Wrexham Industrial Estate in North Wales, the business employs circa 85 people and has a capacity of 75,000 tonnes per annum and manufactures products from mild steel to boron and alloy grades, in various size ranges, choice of coatings and qualities to suit many applications. In addition to its standard specifications, the business can develop bespoke products that can be

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designed, implemented and supplied to suit specific client requirements.

Wrexham Wire’s facilities are equipped with Bullblock, Multiholer, Rotodie and Galvanising production lines (located in the Wrexham Plant), but Cut & Loop, Straightening and Mesh Making can also be carried out in West Bromwich by established service partners. Both continuous and batch annealing furnaces are employed on site and it offers both mechanically and chemically cleaned products.

Wrexham Wire caters to the requirements of the UK market and 60 per cent of sales are exported to Europe and around the world.

The company’s mission is to be the leading European wire drawer in cold heading, bedding & seating, galvanised and engineering wire by providing the best quality and service to customers. The business employs stringent quality control processes at every phase of the supply chain to ensure all goods are manufactured, shipped and delivered in strict compliance to key European standards, including ISO 9001 and ISO 14001.

UK Steel

A large perforated steel filter, taken by Robert Watkins at Croft Filters Ltd in Warrington, winner of the Amateur photographer category of the EEF Photography Awards 2013

elaborates Director, Gareth Stace. “Recently due to the steel crisis the sector has seen a number of job losses during the past year and we have been the main voice of the steel industry in relating its concerns to the Government and to the media.

UK Steel has been focused on highlighting the crisis itself, its causes, what has happened in terms of job losses and market conditions, as well as what we as a sector believe are the solutions to the crisis in terms of what the Government can do to help us and what action can be taken in the UK, Brussels and globally. We would like to create a level playing field for all steel companies globally to compete and trade in what is essentially a global market.”

Gareth Stace

Despite the challenges currently facing the steel industry, steel remains a vital part of everyday life and UK steel producers have invested in the future of steel manufacture as a key component in the development of a sustainable world. Indeed,

steel has been at the heart of more than 100 years of progress and it is anticipated that the material will be equally fundamental to meeting the challenges of the next 100 years. Steel is also the most widely recycled material in the world, with more waste steel recovered in the UK and recycled than all other materials combined. This makes steel a highly sustainable commodity, for example each tonne of scrap material recycled by the steel industry saves 1.9 tonnes of iron ore and 0.6 tonnes of coal. The steel sector also makes a valuable contribution to the UK economy and in 2015 the industry contributed over £2.3 billion to the UK balance of trade.

As the leading voice of the steel industry, UK Steel communicates with government and parliament representatives in both London and Brussels with a goal to influence policy that underpins rather than undermines the long-term success of the steel sector. UK Steel harnesses the power of media to compel the government to take action to support the steel industry and has enjoyed several achievements in recent years. For example, through UK Steel’s intensive campaigning it was announced at the end of 2015 that State Aid approval had been granted for the Energy Intensive Industries Compensation scheme. The package is worth approximately £90 million per annum to the steel sector. The UK Government has also recently committed to permanently exempt the steel sector from renewables policy costs, voted in favour of anti-dumping measures, called an emergency Competiveness Council meeting in Brussels and has pushed for the Trade Defence modernisation package to be accelerated. Furthermore, through the work of UK Steel the Cabinet Office and

others, guidance has been published to ensure social issues are taken into account when procuring major projects, unlocking significant opportunities for the steel sector.

While UK Steel has enjoyed significant success in protecting the interests of the steel industry, the current steel crisis within the UK and globally demonstrates that there are several issues that need to be urgently addressed in the immediate future. “What we have seen when looking at the root causes of the steel crisis in the UK, is that there are three main components that have contributed to its development. For example, the UK steel industry faces unilateral costs that even our competitors in Europe do not face. There has also been a strong pound in recent years that has hurt the UK steel exports globally and finally, over capacity from China and other regions has equally impacted the steel manufacturing sector,” Gareth says. “The intention is not to look for handouts to support a ‘wounded’ industry because we strongly believe that the UK steel sector is one that is able to compete on a global market, although it has also recently found its hands tied behind its back to some extent.”

The unilateral costs facing the UK steel industry include energy prices, where UK manufacturers has previously paid more than double the price for energy when compared to competitors in France and Germany for example.

While in recent years the UK government has taken some action in this area by compensating the UK steel manufacturing sector to the value of £90 million to help lessen the impact of energy prices, the problem of high energy costs continues to persist for UK steel manufacturers.

“The reason that energy pricing continues to be

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Tubes Ltd

S

ince its establishment in 2002, HDM Group of Companies (HDM) has developed a global client base with an extensive annual growth rate over the last six years. Focused on the production of steel pipe solutions, the group has two factories strategically located in MersinTurkey and Cardiff-UK. As part of its growth plan, HDM launched a new spirally welded LD pipe production investment to serve to foundation and construction industries in their Cardiff factory located at ABP docks for UK, Ireland and export markets.

The company can produce up to 3m OD, 32mm wall thickness with special coatings and special design attachments such as clutch/interlock, pile shoes, and rings etc.

HDM also established successfully hollow section and ERW tubes business in UK market in the last 3,5 years from its Cardiff factory; its products are delivered in the UK to different industries such as construction, fencing, manufacturing etc.

HDM Group of Companies also operates a unique facility in Mersin Free Zone / Turkey, where the company focuses on the production of tailor-made foundation pipe solutions.The company is immensely proud of the extensive track records in global foundation solutions that had earned over the years, which continues to grow.

With its new investment in Cardiff, HDM will seek to strengthen its leading position in the foundation pipe market while also sustaining its UK based hollow section business.

Contact Details: Emre Fidan / Ozgur Fidanoglu HDM Tubes Ltd., Longships Road, I-Shed, CF10 4RP Cardiff 07824169760 www.hdmtubes.co.uk

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UK Steel

A steel ingot casting, taken by Ian Spooner at Sheffield Forgemasters, shortlisted in the Professional photographer category of the EEF Photography Awards 2013

“

Theoretically once the UK does leave the EU, the government will have more freedom to set its own rules in investigating the impact of dumped steel on the market deciding the robustness of tariffs

a problem is that it is difficult or even impossible for UK steel manufacturers to pass these costs on to the customer because steel pricing is usually set at a global level, or if not at least at a regional level. Currently despite government assistance there is actually still a gap between the UK steel sector and its competitors in Europe of around £50 million in terms of what they pay for electricity. These unilateral energy costs exist because the UK government has provided funding to renewable energy and introduced carbon and energy taxes, while not paying close enough attention to the impact of this on other sectors, which has resulted in significant job losses in the steel industry,” Gareth explains. “While the government is increasingly aware of these issues, there are other areas such as business rates which are also universally frustrating for UK manufacturers, with UK firms paying five to ten times what our counterparts in Europe are paying. This discourages UK companies from investing in new plant machinery to promote modern business practices and manufacturing and is ultimately a tax on investment. Again the present government has taken an interest in this area and has suggested that UK needs a new industrial strategy, which we feel must look across the board and we hope will remove plant and machinery from the valuation process that sets the level of business rate that a company pays annually.”

One of the most high-profile challenges facing the UK steel industry is that of the influx of under-priced steel products from China and other markets around the world. Over the last

five years for example, the market share of imported reinforcing bar from China into the UK has risen from zero per cent to 43 per cent as a result of excess product being sold into the global market. “The problem stems from the fact that we have had several fast-growing economies, particularly China, which had massive production and therefore a significant need to consume steel.

In recent years the Chinese economy has slowed slightly while its steel production has continued to increase, therefore within a few years the steel industry in the region had developed a massive over capacity. As a result companies increasingly turned to the export market to dump excess steel products,” Gareth reveals.

“Around 12 months ago the UK government was not very supportive of trade defence instruments and nor was it historically supportive of EU proposals to impose trade tariffs on China or other countries. With the appointment of Anna Soubry as Minister for Small Business, Industry and Enterprise during May 2015, within only a few weeks she had expressed a belief that the Government needed to change its position and support fair and sensible tariffs on imports of dumped steel. The government also became more supportive of EU proposals on trade tariffs and on ensuring that these were robust enough to address dumped products, such as reinforcing steel.”

While the government has been more receptive to the needs of the UK steel industry in recent months, the result of the UK decision to leave the EU has created a series of fresh challenges for the steel sector. “I think the headline for the steel sector is that it is going to be more difficult for the steel sector in the UK, however we are looking at how we can turn negatives into positives while looking for further opportunities,” Gareth concludes. “Looking at trade defences for example, theoretically once the UK does leave the EU, the government will have more freedom to set its own rules in investigating the impact of dumped steel on the market deciding the robustness of tariffs. UK Steel is very keen to work with the Department for International Trade going forward to set out what we, as a steel sector in the UK should be and how they should work. We will also work with producers of commodity products in the construction and automotive sectors for example, to promote the increased use of UK manufactured steel over the coming years.”

UK Steel Services: Support to steel manufacturers

www.eef.org.uk/uksteel/

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Silentnight Group

Making dreams a

reality

F

rom its humble beginnings operating as Clarke’s Mattresses Limited in Skipton North Yorkshire, Silentnight Group has become the go-to company for those seeking innovative beds and mattress that promise quality without compromise and, ultimately, a great night’s sleep. “Silentnight Group is the UK’s leading bed and mattress manufacturer and home of the most trusted sleep brands, including Silentnight, Sealy and Rest Assured. We promise a great night’s sleep for all through a combination of market-leading quality, first-class customer service and continuous innovation,” begins Marketing Director of Silentnight Brands, Nick Booth.

“Silentnight, the UK’s biggest bed brand, employs around 750 people at its Barnoldswick factory and makes around 500,000 bed and mattress products each year. With its additional pillow and duvet products, we estimate one in five households has a Silentnight branded product,” he continues.

“While Silentnight is the mid-market family brand that offers a wide range of bed, mattress and sleep accessories for every member of the family, Rest Assured is over 100 years old and one of the UK’s most established bed brands, offering affordable luxury to consumers looking for a more traditional pocket solution. Studio by Silentnight is a brand new offer,

Celebrating its 70th anniversary in 2016, Silentnight Group has become the UK’s leading bed and mattress manufacturer through delivering high quality sleep solutions for all the family

which is targeting younger consumers with a contemporary, style driven solution.”

Keen to remain uniquely different to its competitors, Silentnight Group keeps innovation and product development at the forefront of its operations. This has resulted in the company winning numerous awards such as Superbrands status for the tenth year running in 2015 as well as two Which? Best Buy Awards for two of its mattresses, the Mirapocket 1200 and the 3 Zone Mattress, the same year. In 2016 Silentnight was reawarded the Which? Best Buy Award the Mirapocket 1200, a traditional, double-sided hand tufted 1200 advanced Mirapocket spring system with targeted zoned support for superior comfort. The double sided mattress also features EcoComfort Fibre technology for luxury responsive comfort. Purotex treated to reduce moisture and dust-mite allergens, the mattress is drier, fresher and healthier, earning it the Allergy UK seal of approval.

Able to serve a wide range of customers through its diversity, the main products within the Group’s portfolio include award-winning cot bed mattresses, which recently won the prestigious Mother and Baby Gold Award for quality and premium and pocket sprung mattresses, as Nick comments: “Our core ‘adult’ mattress offer includes the

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Silentnight Group

convenience rolled and boxed Mattress Now collection, which has sold in huge volumes online.

There is also our exclusive Miracoil continuous coil system, which is popularised by the iconic hippo and duck characters, and of course the aforementioned award-winning Mirapocket pocket sprung collection. On top of these products, beds and bed frames are becoming increasingly popular, especially for customers looking for increased storage space in the bedroom. Our clever ottoman storage bases now feature heavily across all brands and are helping to reposition traditional divan bases into more contemporary furniture statements.”

Additionally, the Group’s recently introduced ground-breaking Geltex, a revolutionary gel infused foam comfort layer that delivers new levels of comfort, is rapidly becoming one of its most popular comfort options. By using a unique open cell structure that provides unparalleled breathability and thus allows air to pass through

and prevent the body from overheating with ease, Geltex enables customers to enjoy a full and deep night’s sleep. Moreover, through a unique fusion of gel molecules, foam crystals and air cells, Geltex is significantly flexible and adaptable when it comes to relieving pressure where customers need it most; this innovation helps reduce discomfort from aching joints and also reduces circulatory problems. Alongside these benefits, Geltex mattresses also ensure immediate spring back through innovative elasticity and responds to the individual contours of the body to provide perfect spinal alignment and support all night.

Aware that products must evolve to remain relevant in a changing world, the company holds innovation as an integral part of its ongoing success, as Steve Petrovic, Manufacturing Director at Silentnight Brands, comments: “We work holistically with the commercial side of the business, engaging with the New Product Development (NPD), quality and manufacturing teams to keep feeding the conveyor belt of new product demand. To further support this conveyor belt, we work in partnership with our fabric, foam, fillings and spring suppliers to further develop the principle of a holistic approach to product development. Over the last five years this has seen the Silentnight brands products transform from low value ‘me too’ products to a variety of products covering the needs of all age groups; it has also culminated in a number of awards, including Which? Best Buy.” In addition to developing new products, the

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BekaertDeslee

Better sleep, better life!

BekaertDeslee is a global producer of mattress textiles; tactile, stylish and smart sleep surfaces that inspire, comfort and protect you during the night. Mattress textiles grow more sophisticated, from the fashionable designs on the outside to the increasingly complex engineering and technology on the inside. With Silentnight the company shares a passion for flawless product and quality assurance. BekaertDeslee values the years long partnership with Silentnight Group, a close co-operation of many, innovation and co-creation on all levels and in all departments.

It looks forward to continuing this successful journey together. Congratulations!

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company also focuses on improving quality across the whole supply chain, which significantly includes customer participation, as Steve adds: “Continuous improvement has become organic over the last five years. At the process level, managers are working with their respective teams to drive out issues and foster improvements, which has seen product returns reduced significantly; waste has also been significantly driven down and our business performance is on an upward trajectory. One example of our continuous improvement culture is that we have a weekly gathering of all functions where we tear down a product drawn from stock and critique it; over the last three years this has literally driven hundreds of improvements.”

In line with this focus on quality, Silentnight’s buying team scours the upstream supply chain to ensure the company only buys from credible suppliers. Additionally, the company ensures it is not missing anything that may affect its success by undertaking external audits such as the audit that enabled it to become a full member of the Furniture Industry Sustainability Programme (FISP). Based around sustainable development,

FISP was set up by the government with four main objectives: social progress that recognises the needs of everyone, efficient protection of the environment, prudent use of natural resources and maintenance of high and stable levels of economic growth and development.

To become a member of FISP the company showed commitment to social, economic and environmental sustainability throughout all parts of the business. In addition to this, Silentnight also complied with commitments to environmental management systems, waste management, energy management, packaging management and sustainable timber procurement.

“FISP is very important to the business, as we aspire to be the must trusted brands in our industry, and that means doing things right and letting the retailers and consumers alike know what we are doing is right to further develop that trust,” says Steve.

Discussing another recent audit, Steve continues: “This year we were successfully audited

by Bureau Veritas against the Ethical Trading Initiative (ETI) base code and we passed to a very high standard. This, along with our in-house

Silentnight Group

product testing facility and a management team committed to ensuring legal compliance in all of our activities ensures Silentnight brands keeps driving towards its trust aspiration.”

Keen to maintain these standards throughout the company, Silentnight established an apprenticeship scheme with the goal of replacing an ageing workforce with knowledgeable, passionate and innovative people. Since then, the apprenticeship scheme has gone on to win awards such as Apprentice Provider awards through Burnley College for the last two years as well as a regional award in the large employer category of the National Apprenticeship Awards.

“We currently have 28 apprentices, of which we have recruited 15 in 2016 alone. In total we have had more than 60 apprentices in the business and are already seeing our graduate apprentices moving in to first-line supervision roles,” says Steve. “Such is the scale of our training plans that in the last year we have introduced a full time development and training co-ordinator to improve the management of these young people and tailor our training to ensure we are achieving what the company needs through introducing a modular programme that delivers a broad business understanding before decisions are made on specialising the direction of the trainee.”

Looking ahead, despite celebrating a record sales performance across its Silentnight, Sealy and Rest Assured brands during its last financial year (ending January 30th 2016), Silentnight won’t be resting easy as it seeks to maintain its reputation as the UK’s favourite bed and mattress manufacturer. As five-star consumer reviews across all brands continue to grow and Which?

Best Buy awards further increase recognition in the market, the company will build on the success and growth of the last few years by focusing on

its core values: market leading quality, first-class customer service and continuous innovation. “By understanding the needs of our customers and identifying new trends we will continue to bring new, exciting products to market and further consolidate our position as the home of the most trusted bed and sleep brands,” concludes Nick.

Silentnight Group Products: Beds and mattresses for the whole family

www.silentnight.co.uk

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Automotive Insulations Ltd

Drive for

success

Part of the Autins Group, Automotive Insulations is entering a new phase of expansion after a period of rapid growth

W

ith a history dating back to 1966, the Autins Group began operations as Automotive Insulations, a manufacturer of die cut noise reduction parts for a range of vehicles, and became well known within the automotive sector for producing parts for the original Mini. However, when major client British Leyland ceased production the company faced a challenging period before its fortunes turned around following a management buyout in 2006, as Paul Walker, Managing Director of Automotive Insulations Ltd, begins: “The current CEO Jim Griffin led the senior management team through a period of transition, developing a whole new business strategy. As a result, the Autins Group had a four-year period of rapid growth, which looks set to continue well into the future.

“Meanwhile, Automotive Insulations Ltd continues to provide acoustic and thermal insulation materials to the automotive industry as well as branching out into other sectors such as the apparel, building, rail, aerospace and marine industries. Ultimately, Automotive Insulations Ltd specialises in providing light weight insulation with

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improved acoustic performance primarily for the automotive industry.”

Today combining approximately 50 years of manufacturing experience with state-of-the-art technology, The Autins Group has earned a solid reputation in the market for developing heat and sound solutions across a range of sectors such as automotive, marine commercial and industrial.

Having achieved rapid growth and developed a strong foothold in new sectors, the ISO 14001, OHSAS 18001, ISO 9001 and TS 16949 certified group’s portfolio of clients includes major blue chip firms including Bentley, Jaguar Land Rover, Honda and VW Group.

Within the group is founding company Automotive Solutions, German based Rheinland Insulations, Sweden based Scandins and Indian based Indica Automotive. Together the group forms a team of specialists in noise and heat management that can offer a complete solution to each customer’s acoustic, thermal and NVH manufacturing needs,

a strength that is enhanced through an ongoing investment in state-of-the-art equipment and the most modern technology.

Located at the group’s headquarters in Rugby, the UK, Automotive Insulations is an awardwinning market leader in acoustic, thermal, lightweight and NVH material and component manufacture. It is here that products used in vehicle engine bays, interiors, underbodies and exteriors with a new extended product range of pressed felt, heavy layer, cut foam, moulded light foam and PUR injection moulded parts as well as its traditional die cut and heat sealed parts for noise absorption and transmission loss are manufactured.

Proud to be at the forefront of the manufacturing industry, the company has ensured it maintains this leading position through an investment of approximately £2 million in new machinery as well as a new purpose built 61,000 square foot manufacturing and distribution site.

Operating 24/7, these cutting edge facilities enable Automotive Insulations to undertake a diverse range of testing and manufacturing processes in-house. Moreover, the company’s constant availability means it can respond to customer requirements in a quick and efficient manner, while also providing innovative solutions.

Commenting on these recent investments, Paul states: “Autins Group has invested over £10.4 million in new technology, equipment and premises in the past two years and the group now leads the way in several niche manufacturing processes including cut and seal technology, lightweight acoustic solutions and composite

solutions, many of which are based at Automotive Insulations Ltd. The group has also recently set up a research and development facility, Autins Technical Centre at HORIBA MIRA Technology Park, which will enable Automotive Insulations Limited to test and refine materials in-house.

“As a result of this investment, staff numbers have risen from 40 in 2012 to 240 in 2016 and turnover has increased rapidly from £5 million in 2012 to £19.9 million in 2015/16, with further sales agreed that will enable the business to grow further.”

Not a group to rest on its laurels, Autins Group has gone on to commission a £4 million factory in Tamworth under its new subsidiary Solar Nonwovens, which will focus on providing customers with the group’s latest product Neptune. Using new technology from Korea, Neptune is a new high performance, lighweight and micro-fibre insulation material for the automotive market that will only available in Europe through Solar Nonwovens. As part of this major investment, the group has shipped over a new cutting edge machine from Korea, which was transported in 14 containers, with the goal of having a saleable production running at Solar

Nonwovens by the final quarter of 2016 and full production of up to three lines in 2017.

Paul highlights the benefits of this major development in Autins Group’s history: “By supplying a comprehensive package the overall result can be tuned to meet and exceed the customer’s expectations and the production of

our new Neptune product gives us the flexibility to produce custom grades of material weights with a range of surface materials to suit each client’s requirements.”

Benefiting from a strong foothold in the thriving automotive market, the Autins Group is in an advantageous position moving forward not only as the exclusive European supplier of Neptune but also as a group with a strong reputation for delivering cost effective, high quality solutions to customers. As it seeks to gain certification to UKAS in 2017 that will enable its technical centre to carry out testing for external companies and in-house research and development, Autins Group’s goal of becoming the supplier of choice within the markets it operates is certain to become reality over the coming years.

Automotive Insulations Ltd Products: Acoustic, thermal, lightweight and NVH material and components

www.autins.co.uk

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TOS Varnsdorf a.s

License to

mill

Steeped in tradition, TOS Varnsdorf has used its century of experience in horizontal boring and milling machines to become a trusted manufacturer to customers across the globe

S

ituated in Varnsdorf, Czech Republic, TOS Varnsdorf a.s (TOS Varnsdorf) was originally founded in 1903 under the name Arno Plauert Works; while operating under this name, the company produced various types of machines such as horizontal lathes and grinding machines before realising the strategic advantage of specialising in a specific product.

Following years of product development, the company today boasts an impressive product portfolio, which has been segmented into separate divisions: horizontal milling and boring machines, floor type horizontal boring mills, machining centres and special machines; there is also a segment for accessories, should customers require items such as milling heads, milling attachments, add-on tables, clamping equipment, standard accessories and tool cooling.

Alongside this range of products, the

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company also offers a wealth of services to customers; this includes technological solutions, where customers are offered information on the machine’s optimum configuration and most suitable technology to be used as well as a time study and list of suitable tools and clamping elements. TOS Varnsdorf also offers customers machine installation, training for operators and maintenance workers, programme training and technological studies. Other services include financial support, shipping and a rapid, high quality machine commissioning service in addition to machine modernisation, general overhauls, medium scale repairs and minor repairs of the machine.

This commitment to delivering a thorough and reputable service to customers has resulted in strong sales across the globe in a wide range of industries such as energy, oil and gas, mining, construction, transport shipping and even glass.

Approximately 50 per cent of TOS Varnsdorf ’s customers are based in Europe, however it has also developed a strong foothold in the US, South America, South East Asia and particularly China, where it has established a daughter company that delivers approximately 30 machines a year to clients in this booming market.

Discussing the company’s activities, Michal Machacek, Head of Marketing at TOS Varnsdorf a.s begins: “Today our core business is not only manufacturing and selling horizontal

boring and milling machines, of which we produce approximately 140 per year to our customers across the globe, but also the development of the machine as well as a warranty service and overhaul of machines. Our portfolio is mainly comprised of three groups of products, the first of which is table type horizontal milling and boring machines; this means that the machine is small and light enough to move and fit on a table and also means that the weight of the work piece is between five and ten tonnes. The second product group is floor type horizontal boring mill machines, which must be clamped to the floor on a special surface of cast iron pieces with clamping equipment. The third type of product available is a machining centre; these products are much like the first group because they are table type, however they are designed for up-to-date technologies.

“When it comes to recent product developments, in 2014 we produced the first prototype of the WHR 13 CNC and WRD 13 CNC machines, these are family machines from the same frame parts and were developed in accordance with demands from our sales representatives. To get these machines developed in one year was their first target for us and since their development and launch into the market sales have been positive across the globe. So far we have produced 25 machines and now have many new orders, so these steps in our production proved highly fruitful for us,” he

adds. “Meanwhile, in 2015 we launched our first machine with hydrostatic guideways; this was a big project for us as we have no skills in hydro, but the final development was perfect. So far we have produced two of these machines and we expect further positive results over the next few years.”

Not a company to rest on its laurels, TOS Varnsdorf is in the process of testing a mechatronical concept, as Michal notes: “Our machines are quite big, the machine part can be up to 30 metres in size and in this big cube we achieve accuracy in hundreds of millimetres, which is the standard level. However, with the mechatronical concept, we can provide accuracy in thousands of millimetres, which is more superior. Carried out by an independent measurement system on the machine, according to the information provided, the control system

can adjust the machine and correct the errors.

This concept is available to standard production programmes as we can customise any machine for our client’s demands, such as a need for inprocessing measurement.”

Offering time and cost savings to customers, this mechatronical concept is certain to increase in demand as customers realise they will benefit from no longer having to move parts to the coordinate measurement machine that controls the shapes and data of the workpiece and will instead be added with new technologies without any transportation required.

Proud of its ability to deliver a complete customised solution to customers, the company will naturally continue this tradition for delivering satisfaction by maintaining a focus on enhancement, not only in product innovations

but also in customer service, as Michal concludes: “In the past we have had issues with quality of service. Now we have twice annual meetings with representatives across the whole world who come to our company and see what changes need to be made. In line with these meetings, we are currently focusing on improving skills when it comes to motivation, communication and leadership. These are areas we will focus on enhancing over the coming years.”

TOS Varnsdorf a.s Products:

Manufacturer of horizontal milling and boring machines

www.tosvarnsdorf.cz/en/

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M Squared Lasers

Solstis optical table

Lighting the

way

M Squared is a photonics technology company and it’s on a mission to harness the power of light to improve our world through the design and manufacture of advanced, laserbased photonics technologies and related applications

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M

Squared is at the forefront of technological advancement, with a wide range of applications and mix of customers around the globe. Chief executive officer and co-founder Dr Graeme Malcolm explained the core elements of the business: “We design lasers and laser-based instrumentation using cutting edge photonics technology. We focus our efforts in three main areas: quantum technology – which is really the future of electronics: we had analogue with valves, digital with computing and smart phones, and now quantum – the

next big technological breakthrough. We are at the point where quantum science allows us to enable newer, more advanced and previously unimaginable applications. We also focus on lasers for chemical sensing, using our lasers to detect chemical agents and their chemical composition – so looking for things like explosives or chemical warfare agents, or even for standard industrial chemicals, oil and gas, or food and drink. The final area is biophotonics, which is the use of lasers for healthcare applications. Our new form of microscope can observe biological material at

Solstis engineer ing drawing

Dr Graeme Malcolm

a cellular level, so we can look at individual and larger groups of cells. For example, this enables neuroscience to see how neuron networks join up and further our understanding of how the brain works – we hope this will one day lead us to cures for diseases such as dementia and Alzheimer’s. Those are our three key themes, but there is really a whole plethora of interesting applications being born from our technology.”

One exceptional side to M Squared is its dedication to innovation and advanced manufacturing techniques, which Graeme explained: “We manufacture all our products

in-house and really challenge ourselves to go further developing new techniques, using new materials and creating advanced software. One example of this combination of hardware and software is the development of a microscope system that is able to image large volume specimens (such as brain cells in neural networks) over long periods of time – this will really help scientists study what is happening to them. This new technology will have uses that range from developing greater understanding around neuroscience, as well as for cancer biology, or for pharmaceutical research.”

Thanks to the hard work done at M Squared, it received a Queen’s Award for Enterprise in Innovation this year, an achievement Graeme commented on: “It’s real recognition for the team and great for the business. It was awarded for our SolsTiS laser platform– a toolkit that is helping scientists explore the quantum realm. It

has been responsible for enabling the progress scientists are making in quantum and is already being used in the world’s most accurate clocks, to teleport information, in antimatter experimentation and in the construction of ‘ion-drives’ (the next generation of space propulsion).”

The company works hard to continually improve and innovate, and in order to achieve this M Squared places a high priority on research and development, which Graeme highlighted: “We take a very open collaborative approach to innovation. We structure the business with an 80 per cent focus on making world-class products and 20 per cent on innovation. There are 25 members of staff focusing on research and development – currently we’re running in the region of 25 collaborations on projects worth around 20 million pounds. Over the last five years we have collaborated with more than 70 different groups worldwide – places like Oxford, Cambridge, MIT, Stanford, Max Planck Institute in Germany, and University of Copenhagen.

The work we do in this area will undoubtedly provide future growth for the business.” M Squared also works hard to recruit new people into the industry by going to universities and giving talks, as well as conducting outreach work – this is to ensure that the next generation of specialists in laser technology is developed.

It is no wonder then that M Squared’s products have extensive uses for highly

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M Squared Lasers

Zebrafish Gaussian Air y compar isons

Ashgill Electronics Ltd (AEL) Ashgill Electronics Ltd (AEL) has provided contract manufacturing services to the electronics industry for over 45 years. Global parts sourcing and procurement coupled with PCB assembly and test using modern equipment, ensures products competitively meet the most demanding of environments.

Recent investment in additional, SMT, Selective Soldering and AOI equipment, means the company is capable of placing in excess of six million parts per day. The current development of a small business unit to support prototype and product development, makes AEL the ideal, cost effective solution for all PCB assembly needs, from small prototype runs through medium and higher volume production

34 www.manufacturing-today-europe.com

technical research and day-to-day uses, and the position the company has in the market was something Graeme discussed: “We are seeing a growing demand in sensors, computing and communications – China has launched a satellite that has quantum key encryption in it, so these technologies are getting adapted and used rapidly. I think this is going to be like the digital revolution, like the semi-conductor was decades ago.”

The business is ready for these upcoming developments, and Graeme explained that it is in a strong position: “Overall last year our revenue was about ten million pounds and

typically we are doubling every couple of years.

So we have a high rate of growth in the business and at the moment we have about 80-85 employees that are split between the UK, US and Germany where we have local offices.”

M Squared has already reached the milestone of a decade in a fast moving industry, and the plan for the future is exciting, which Graeme provided a brief insight into: “The step-up is integrating laser systems and developing photonics technology. This is the big opportunity for us because it opens up areas where we can solve big problems.” M Squared is without doubt a company that is forging the technology that will play a major role in the world, from the average person’s laptop or phone, to amazing breakthroughs in international medical research.

M Squared Lasers Products: Advanced laser platforms, lab instrumentation and novel photonics systems and applications

www.m2lasers.com

Munck Cranes AS

Weighing up

opportunities F

ounded on 25th October 1924 by Mr Sverre Munck, an educated electrician engineer from the University of Trondheim, Munck AS initially began as a trading company with products ranging from fuses and lightbulbs to escalators, elevators and electric wire rope hoists.

With the first manufacturing plant completed in 1946, the number of employers significantly increased from 30 to 300 people, which was mainly due to the result of a major contract to make 18 units of trolley buses for Bergen Sporveier, the local bus company. It was during this milestone in the company’s short history that the Munck electric wire rope hoist was designed and full production commenced, which involved hoists, industrial cranes for all types of industry onshore as well as onboard vessels.

A pioneer within the Norwegian export industry, the company exported its first hoist to Sweden in 1948, which was shortly followed by another two to England; since then, export to overseas became a rapidly growing market for Munck. In response to this, subsidiary firms were set up in locations such as the US, Canada, the UK, Sweden and Belgium and a network of agents were established in other strategic areas across the globe.

Taken over by the family company Furnes

By focusing on customer satisfaction, enhancing quality and the continuous development of its products, Munck Cranes AS has become a leading manufacturer of cranes in Norway, the Nordic countries and Northern Europe Hamjern Holding AS in 1996, Munck Cranes AS today owns two separate companies, Munck Kraner AS Danmark and Munck Cranes AB, in Sweden and continues to work closely with its subsidiaries, which are being managed by local owners.

Representing experience and competence, Munck Cranes AS has grown to become one of the main producers and suppliers of cranes and lifting equipment in Norway, an enviable position that was earned through a continuous focus on quality, development and innovation. Capable of delivering equipment for lifting loads of up to 500 tonnes, the company is viewed as a total supplier of cranes and material handling equipment for a broad range of industries, both in Norway and further afield.

Discussing the company’s product portfolio is

Rune Vabø, Managing Director at Munck Cranes AS: “Our main product can be divided into four segments: service and maintenance, standard cranes, automatic crane systems for offshore installations and offshore special equipment.

Within the latter division we are strongly involved in supplying winding turntables, in fact, we are currently producing two large turntables with a load capacity of 16,000 tonnes.”

This current contract follows the company’s recent involvement in a number of notable projects, including the delivery of three Munck semi gantry cranes with an operator cabin mounted to a centre fixed column as well as a six tonne column crane with arm length of seven metres and a column height of 11 metres. This cable handling system was mounted to a turntable used for storing umbilicals in Norway five months ago.

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Munck Cranes AS

Loman

LOMAN is one of the leading suppliers for CNC machined components in Slovakia and has been working with Munck Cranes over six years.

During this time the relationship between the two companies has grown enabling LOMAN to become an important supplier for Munck Cranes.

High quality and good prices on one hand, seriousness and fairness on the other hand create a strong partnership. It is a pleasure to work with company that shares its core values.

Although Munck Cranes has seen steady growth in demand for its winding turntables, the company’s main products are overhead travelling cranes and hoists. “These products continue to be our bread and butter; we have our own range of hoists that we use for a range of things, these have a capacity from under one tonne to 100 tonne. We also have these heavy duty cranes that we can’t use as a standard hoist; the biggest one in production at the moment is 220 tonnes.”

Also known as automatic cranes, overhead travelling cranes offer customers in the process industry advantages including increased security and lower operating and maintenance costs.

Plants handling hazardous waste also use automatic cranes instead of fork lift trucks and conveyers to ensure all crew work in the safe zones of the facility. Because these cranes are part of a

computer system that operates throughout the facility, these automated cranes offer notable advantages. For example, the waste in an incinerator plant can be reduced significantly as a result of the main computer being provided with the exact information on the volume of garbage, which is then fed into the incinerators.

Suitable for locations such as glass processing plants, composting plants, galvanization plants, zinc production factories and incinerator plants, Munck Cranes’ automatic cranes would be a beneficial addition to any company’s facility.

Meanwhile, Munck Cranes offers a variety of hoists that are suitable for all kinds of lifting, with wire electric hoists frequently used for heavy loads between 630 kg to 108,000 kilos, while its chain hoists can be manually driven or electric; these are mainly used in lifting of a load between 40 to 20,000 kilograms. Within the electric wire hoist range is the electric wire hoist 31-series, which are specifically designed to meet the challenges of precision lifting material. Following rigorous tests, this new range has met Munck Cranes’ high standards for quality and boasts a robust design and limited need for service – integral factors that lead to low maintenance costs. Although the Munck standard hoist range covers 630 kg to 108,000 kilos, Munck Cranes is also able to create solutions that offer lifting capacities of up to 500,000 kilos; these units are built from superior quality components and offer the same economical advantages as the standard programme. As expected, all components comply with international standard such as EN-NS, FEM, ISO, CMAA and HMI. Renowned for its commitment to quality, the company has recently been involved in a number of notable projects and even beat competitors to become crane supplier to the 20 million Norwegian Kroner (NOK) Follo Line Project in Oslo, Norway. As the largest infrastructure project in Norway, it involves adding four tracks into the

capital of Oslo, which will offer more trains as well as faster trains on schedule. The project will also include a 20 km long tunnel that will become Norway’s first long twin tube rail tunnel.

Although its wide range of high quality products have cemented Munck Crane’s reputation in the market, Rune says it is the people behind the cranes that make the company special: “We have the knowledge, focus on quality and commitment to customer service to ensure problems are solved or new options are provided to clients.

Our key customers are the moment are in the energy, oil and gas and aluminium sectors; for these customers we want to become stronger in all four segments of the business, to enhance our service and standard equipment and also our special handling equipment for the offshore sector.

“There is a great deal of potential in the energy sectors, not only in Europe but also the wind industry across the globe; we have also seen an increase in demand for our automatic cranes in waste industries. Despite problems due to oil prices and exchange rates we have come out of these challenges strong; it is our goal to continue getting stronger,” he concludes.

Munck Cranes AS Products: Cranes and lifting systems

www.munck-cranes.no

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Tele-Fonika Kable

Keeping

connected

Ranked in the forefront of the global cable industry, Tele-Fonika Kable SA (TF Kable) is the third largest manufacturer of cables and wires in Europe and sells its products to over 80 countries

E

stablished in April 1992 in the city of Myslenice, in close proximity to Krakow, Tele-Fonika civil par tnership company began by constructing a modern and stateof-the-ar t production plant that specialised in the manufacture of copper, computer and fibre optic telecommunication cables. The company swiftly became a leading supplier in the Polish market and took the strategic decision to maintain its position in the market by initiating the production of advanced copper telecommunication cables that allow for data

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transfer in a bandwidth up to 100Mhz at a maximum speed of one Gbit/s.

With market demand for its products booming by 1996, the company began doubling manufacturing capacity for that product group.

One year on, the company progressed into the production of fiber optic cables and, following the purchase of advanced equipment

by Nokia Maillefer, TF Kable was able to produce up to 216 strand fiber optic cables. To fur ther strengthen its foothold in the market, Tele-Fonika SC acquired a majority stake in Krakowska Fabryka Kabli SA (KFK), which

Zumbach Electronics

On-line measurement, monitoring and control equipment since almost 60 years

specialises in rubber isolated cables.

These developments resulted in the commissioning of a modern, automated and robotic production facility in Krakow Bieżanów; this facility focuses on flexible highly stranded conductors, aluminium wire rods, aluminium alloy overhead aerial cables; trolley traction wires and PVC and building wires.

With the acquisition of a majority stake in Elektrim Kable SA finalised in December 2001, a new entity was formed - Tele-Fonika Kable SA (TF Kable). As a result of two plants Bydgoska

Fabryka Kabli and Fabryka Kabli Załom became part of the Tele-Fonika Kable Group and Ożarowska Fabryka Kabli was closed.

Following fur ther business developments, TF Kable today is the largest wire and cable manufacturer in Poland, operating from six production facilities and boasting a significant local market share. Benefiting from its impressive manufacturing capabilities, the Group produces approximately 25,000 different products for its broad customer base, as Bar tlomiej Zgryzek, Vice President at

A pioneer of on-line measurement, Zumbach Electronics from Switzerland manufactures a comprehensive range of non-contact, on-line measuring and control instruments. Its technology is in use world-wide for such dimensional parameters as diameter, thickness, eccentricity, out-of-round and for physical or electrical parameters like expansion, capacitance, dielectric strength, and more. One or more parameters of a production line can be monitored simultaneously.

Zumbach technology is used successfully in these industries by thousands of customers around the world who rely on the quality and reliability of the company’s instruments and systems: In the cable industry – for telecommunication wire, data wire, power cable, electronic and control cable, fiber optic cable – on extrusion lines of singles and jackets, CV-lines, rewinding stations.

In the plastics and rubber industry – for the extrusion of pipe, tubing, hoses and profiles for automotive, medical, hydraulic, plumbing, construction products and more.

In the steel and metal industry – on hot rolling mills as well as in cold processes for steel and other metals.

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Tele-Fonika Kable Desma

DESMA realises machines and systems for the production of technical rubber and silicone moulded articles. The DESMA turnkey plants make demanding products that seal up, dampen, fix, insulate or protect.

In order to manufacture them successfully, DESMA puts excellent technologies and service performances worldwide on the customers’ side. The development of the innovative product range SmartConnect 4.U allows production processes to be realised in a more flexible, efficient and resource-friendly way by applying intelligent networking. The new systems make a higher plant and machine uptime, a more transparent and improved product quality or piece cost oriented production efficiency possible. A claim which the market leader DESMA of course lives up to – in the light of increasing customer requirements and dynamic market developments.

Tele-fonika Kable highlights: “The products offered by the Group are classified into six main categories: 1 kV cables, medium voltage and high voltage cables, telecom cables, wires, rubber isolated cables and other cables. Sales on the Polish market account for approximately 40 per cent of total revenues, with sales in foreign markets generating the 60 per cent; the core markets are Germany, the UK, the US and Baltic region countries.”

He continues: “The main customers of TF Kable include wholesale network distribution companies, energy companies such as power plants, utilities and network operators; companies in the oil & gas and mining sector, the telecommunication segment, which includes telecom operators and their suppliers and large industrial companies.”

Operating from six production facilities, four of which are based in Poland, the Group made the strategic decision to go through a reorganisation process in 2013 that has led to each production plant in the country specialising in specific types of cables; this decision has enabled TF Kable to not only improve cost controls when it comes to production, but also logistics and sales processes.

“TF Kable’s main competitive advantage lies in our high quality products and operational effectiveness,” says Bartlomiej. “Therefore, we have to compete by carefully controlling our operating costs above all as it seems to be the key to commercial success. The operational excellence is strongly supported by the complete specialisation of our production plants.”

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Tele-Fonika Kable

BWE

BWE Ltd is a British engineering company specialising in continuous extrusion machines and cold pressure welders for many different applications.

Conform and Conklad are well-established continuous extrusion technologies in the non-ferrous, cable and tube industries. Typical applications include Copper & Aluminium Rectangular Wire (Magnet Wire for Transformers), Solid Aluminium Conductor (SAC for cables) Copper Bus Bar, Trolley Wire and other shaped conductors, AS Wire, OPGW, CATV, Round Refrigeration Tube, Multiport or PFC Tubes in different alloys.

With seven lines currently in production, BWE’s SheathEx technology is fast becoming the new alternative to seamless aluminium sheathing of high voltage cables.

The SheathEx process provides a continuous (no stop marks), reliable (no weld) and cost effective (cheap materials, low energy etc) method of sheathing high voltage power cables.

A new Conform machine has been specifically designed to extrude Solid Aluminium Conductor (round or sector shaped) from 2 x 9.5mm diameter rods, providing a cost-effective process to a product in demand.

A new Conklad machine has been added to the range, enabling small and delicate cores to be sheathed from one aluminium feedstock rod instead of two. The machine will reduce capital and running costs for applications such as AS Wire, OPGW, Sheathed Composite Cores, Reinforced Aluminium Wire and Solid Aluminium Conductor (SAC).

BWE continue to manufacture and supply a complete range of cold welders and dies for a fast, cost-effective and reliable solution to welding non-ferrous materials from fine wire to round rod.

SheathEx, Conform and Conklad are Registered Trade Marks of BWE Ltd.

SAMPSISTEMI

Founded in 1936, Sampsistemi has gradually grown to become the only company worldwide able to provide customers with the complete wire and cable process chain. With Italian roots and a worldwide presence, Sampsistemi embodies a philosophy of constant care for the environment that, combined with extensive application know-how, has always driven the evolution of the company’s products.

All over the world, Sampsistemi supports its customers with the best possible solution in terms of reliability, quality, innovation technology and cost reduction thanks to local companies located in Italy, China, the USA, Russia and India.

In more detail, the Group’s Myslenice plant today specialises in the production of telecommunication cables, while Krakow Bieżanów specialises in processing copper and aluminium rods as well as manufacturing semifinished products such as copper wires and cords. The Krakow Wielicka plant, meanwhile, is the largest cable producer for the power industry in Poland and produces a wide range of cables; these include power cables, control and signalling cables and special purpose cables such as rubber isolated cables. Bydgoszcz specialises in the production of power cables as well as self-suppor ting and suspended cables, fittings and power cables. The two facilities that are abroad, Zajecal, in Serbia, and Czernichow, Ukraine, both specialise in low voltage cables, however, the Zajecal plant also produces building wires and rubber isolated cables, while Czernichow also manufactures building wires.

The massive diversity of products and

the superior production capability of plants has resulted in the Group’s involvement in a number of major projects. For example, in 2011 the Group supplied power to one of the main Euro 2012 arenas, the National Stadium in Warsaw. For this project, the Group’s Bydgoszcz plant manufactured speciality high voltage cables, rated 110kV, with fiber optic cables; the cable line was approximately 510 metres and was installed in a conduit running under the Vistula River, cable conduit installation took place through the utilisation of Horizontal Directional Drilling (HDD).

Proud of its commitment to shared principles and objectives when it comes to the ethical, sustainable and high quality cable development and manufacture, the Group became a member of Europacable, signed the Europacable Industry Char ter in September 2015 and the CEO of Tele-Fonika Kable became the Vice-President of the

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Tele-Fonika Kable

Europacable Association. Having joined the ranks of Europacable, the Group not only gets oppor tunities to network with representatives of other cable market players, but also gains additional knowledge when it comes to respecting product quality and safety.

Consistently focused on operational excellence and the delivery of high quality products, TF Kable anticipates fur ther growth in the future following positive changes in the market since 2014. In response to these oppor tunities, the Group will fur ther develop and expand its vast product por tfolio with more complex products such as MV and HV cables and cables in line with European CPR requirements, which will thus enable it to meet the increasingly challenging needs of its customers across the globe.

Tele-Fonika Kable

Products: Copper and aluminium cables and wires and optical fibre cables

www.tfkable.com/en

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RS Motorhomes

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With 25 years experience in the manufacture of bespoke luxury motorhomes, RS Motorhomes has established itself as an award-winning leader in its field of expertise

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fficially established 25 years ago, Yorkshire based, family owned business RS Motorhomes’ history dates as far back as 1982 when Managing Director Mick Rowe built his own motorhome for motorsport. This soon became a desirable product that has gone on to become world-class with global demand. Since these early developments, RS Motorhomes has progressed from supplying specialised motorhomes to the motorsport market and expanded, with significant success, into the leisure market.

“RS Motorhomes has established itself as an award-winning bespoke luxury motorhome manufacturer that now builds motorhomes for all kinds of needs; these include motorsport, which is mainly motorcross, however we do also provide vehicles for racing cars, quads, buggies and many other racing platforms; leisure and disability,” says Mick Rowe, Managing Director of RS Motorhomes. “Today we hold 80 per cent of the UK niche/completely bespoke motorhome market, selling to all corners of the UK and further afield.”

As a renowned leader in delivering high

Endeavour

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Equinox

Accurate Laser Cutting (SJS)

Accurate Laser Cutting (SJS) Limited is a leading UK provider of laser profiling & pressbrake services. From its manufacturing facility in Rotherham, the firm services a wide range of industries with its advanced laser cutting & forming capabilities. A recent investment project, introduction of a dedicated night shift & increased production capacity ensures customer demands are met quickly & efficiently, offering some of the shortest lead times in the industry. With potential new investments on the horizon, Accurate Laser Cutting (SJS) is set to continue to offer an unrivalled laser profiling service for many years to come. Enquire today for all of your sheet metal needs.

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quality products created from exceptional designs and an ongoing commitment to innovation, the company continuously strives to ensure that owning one of its vehicles is as fulfilling as possible for customers. Because of this, customers receive the same level of care and craftsmanship for each project, whether the client is requiring a 40 foot motor race support vehicle, motorhome or a van conversion.

According to Mick, RS Motorhomes’ customer centric approach to business is key to ensuring optimum customer satisfaction during the process of production: “AT RS Motorhomes we can do just about anything the customer wants to a vehicle, from smaller bespoke items such as hydraulic leveling legs to extending slide outs to being able to fit a racing car in the back of the vehicle; in fact, we have built vehicles where the whole back lifts up to unveil a large garage space fit for a whole racing team.

“To make this possible, we work extremely closely with all of our customers, as each vehicle is completely bespoke we ensure that we have as much input and communication with clients as possible. The customer will regularly visit our design team and production plant throughout a

Emotion

RS Motorhomes

Eros home

project to ensure we deliver a vehicle to their exact specifications.”

Operating as both manufacturer and dealer, the company is able to react to a customer’s requirements and welcome their input; it also encourages both existing and potential clients to visit the facility and see for themselves the level of quality that can be appreciated by experiencing an RS Motorhome as well as the services on offer.

Within the company’s RS model range, from smallest to largest, is Eros, Equinox, Endeavour, Evolution, Envoy and Emotion. Discussing the manufacturing process, Mick states: “We always use the latest chassis from either Iveco or Mercedes-Benz; a model we are particularly proud of is the Elysian. In fact, we are the only UK manufacturer of an A-Class, and the amount of design and technology that goes into this model is staggering. During manufacture, we completely transform the chassis, giving the vehicle a new face that we make on-site in the fiberglass shop.

“Within our range of products, the RS Elysian is a high quality, great value for money motorhome; we are proud that customers come back year-after-year to replace their older model with the latest version.”

Injecting a high level of passion and charisma in every item it makes, the company’s employees are driven to building the perfect motorhome and, as such, each product is built by hand with the enthusiasm and care for detail that the customer deserves. “We have a very

strong team that will always make sure each vehicle rolls out of the factory no less than perfect. From quality control officers to lean manufacturing managers, we will do everything we can to ensure that customer satisfaction is achieved,” says Mick.

Following solid sales levels in 2015, with more than 10,500 new motorhomes registrations and sales reaching pre-recession levels that were the highest annual figure since 2007, RS Motorhomes is in an enviable position as the UK becomes one of the fastest growing markets in Europe for motorhomes. Moreover, the currency difference between the euro and sterling gives the UK leverage as an ideal place for European manufacturers to invest in; with all of these positive developments, it is anticipated that sales in the UK in 2016 will exceed those in 2015 and thus offer RS Motorhomes ample opportunity to strengthen its foothold in both the UK and beyond.

“Our goal over the coming years is to continue our expansion into Europe and are also looking at growth in areas such as South East Asia with potential partners. We have been very successful in the UK market and our longterm goal is to achieve this success overseas.

To do this we aim to design and manufacture motorhomes across the world, meeting the expectations of customers like we have here.

Ultimately, we want to design products that continue to exceed the competition and guarantee that the customer returns year-onyear,” Mick concludes.

Elysian

Emotion

RS Motorhomes

Products: Motorhomes and specialised vehicles

www.rsmotorhomes.com

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Summitglow Ltd

Many irons in the Summitglow Ltd is a heat treatment specialist that continues to expand and steadily grow and as such takes advantage of both traditional and new technologies

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fire

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he past few years has been a testing time for many of those connected to the oil industry, though there are those that have managed to continue to achieve growth, and Summitglow is one of them. The company provides a wide selection of specialised heat treatments and supplies these to a range of industries. Summitglow has made further improvements and investments to the business, as well as devoting focus to diversification and expanding into more markets, which demonstrates the strengths of Summitglow and how well it can perform even during a more challenging period.

The company was set up in Sheffield during 1983, and it was a family owned business – something it continues to be to this day.

Summitglow originally provided salt bath heat treatment services, though due to a sustainable growth plan it evolved – it now offers unique

and specialised heat treatment services by using cutting edge technology and a dedicated small team. At the present time Summitglow offers services that range from vacuum, salt bath, case hardening, gas nitriding and nitrocarburising, to sub-zero (cryogenic) and air and atmosphere treatments, in addition to hot chemical blacking and straightening services. Having been established in 1983, the company has already achieved the milestone of over three decades of activity, and with further investments and larger demand for its products - attaining five decades or even a century in business seems likely.

Summitglow has previously been featured in Manufacturing Today Europe during 2015, in that piece managing director Philip Watkinson discussed that the company was looking into the opportunities that opening a new furnace would provide: “The vision is, and has been for a while, to progress further into doing more high-end,

high-complexity components that require high tolerances and better quality. By pushing for higher technology, higher quality, high-end markets, whilst maintaining our spread of markets, we will be able to continue to grow,” he said. This development has since come to fruition. Summitglow now has a fully functioning new furnace, something that in the most recent interview Philip expanded on: “It has given us a lot more capacity than we had previously, because before we only had vacuum capacity for small turn around batches, whereas now we can handle much larger requests. We can actually do a lot more than just a greater sized batch with the new equipment, we can also provide for different shapes, and new varieties of components, all of which we couldn’t handle before. This is all really positive, it means that we can do more work for our existing customers – that before we were not able to commit to – it also means that it opens doors with new customers that had demands we couldn’t meet previously.” It is clearly a positive sign that the company has continued to invest in its facilities, which will then in turn make it more attractive to a wider market, and thus ensure that the Summitglow is in an increasingly stronger position in the future.

The business is willing to make investments in order to increase its product range and quality, and this has proven to be a worthwhile tactic – leading to the company growing and appealing to more markets. After the successful launch of the new furnace there are plans to improve another side of Summitglow, something that Philip elaborated on: “We are looking at increasing some of our nitriding facility next year, the plan is that during 2017 we will have another nitriding furnace – smaller units will then be replaced by a more versatile furnace that is slightly larger with a much quicker heat up time and a vacuum tempering furnace, those are the two main things we are looking at for the moment.”

There are many factors that are crucial to any business working within the

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Summitglow Ltd

industrial sector, but two essential ones are safety and the assurance of quality. Both of which Summitglow takes seriously and places as a top priority. It has already achieved previous accreditations, such as the ISO9001:2008, but Philip explained that the company is not sitting idle on these matters: “One of the main projects at the moment is we are working towards is ISO9001:2015 and we plan to have that in place by the middle of next year, we certainly expect for that to be in place by our next audit in July. It is going really well, and we have utilised some external help to achieve it. It is a significant change to the current standard but any improvements to quality is something we welcome and embrace.”

The company has high hopes for the coming 12 months due to the combination of improved equipment, expanding markets, and the business growing in general, this ambition was something that Philip expressed: “At the present time I don’t think we will pursue rapid expansion, however we do plan to have sustainable and continued growth. We aim to achieve consolidation and growth within existing markets

– and still continuing to push towards improving our reputation in different markets. There will always be some areas that are declining and others that are improving, so the expansion for us at the moment is definitely within vacuum.”

Summitglow is taking a very pragmatic and stable approach, it is not overstretching in a market that can fluctuate, and instead it is appealing to a variety of sectors, this will protect the company’s success in the future.

It has been a tough period for many companies that provide for the oil industry, however Summitglow is not delivering a message of doom-and-gloom – instead it is quite the opposite, it is building on what it has previously done to provide an even better standard. It is appealing to larger markets, and it is has a realistic plan for the coming years that will see steady growth. It will no doubt be a glowing beacon of success and diversification.

Summitglow Ltd Services: Salt baths, sealed quench furnaces – hardening, case hardening and carbonitriding, belt furnaces – hardening, case hardening and carbo-nitriding, vacuum furnaces, hardening, ageing, gas nitriding furnaces – up to four metres capacity, nitro-carburising furnace, hot chemical blacking, sub-zero (cyrogenic) treatments

www.summitglow.co.uk

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AR Metallizing NV

Listen, learn and

lead

AR Metallizing NV is a world leader in the production of metallized boards, papers and films used in the consumer packaged goods (CPG) sector. Its core focus is labelling and flexible packaging

Bart Devos, CEO

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s Bart Devos, CEO, explained, alongside these items the company also develops complex specialty products, including metallized textiles and substrates for the automotive, sports gear and equipment, medical and construction sectors.

“For instance, the company provided the UV reflecting textiles for the Bangkok Airport roof construction,” he highlighted. In fact AR Metallizing’s range is very extensive. The core focus is labelling and flexible packaging, which are supplied to an array of clients including printers, laminators and converters as well as the top tier brands in the food and beverage, entertainment, media and advertising sectors. The product portfolio also includes a range of envelopes and gift-wrap solutions. , “Our range is actually quite vast,” added Bart. “We work closely with clients to help them develop solutions, and so for example, we’ve been working with a chain of quick serve restaurants to replace their existing nonenvironmentally friendly packaging with a greener solution.”

“We also help our clients in the designing of their labels and packaging,” noted Jacky Vanden Ecker, Operations Director. “We have an in-house creative services department with a marketing design specialist who helps new customers and existing label and packaging customers to design specifically on metallized paper because design is always different on these materials.”

“We have the reputation in the market to be innovators,” Bart continued. “A great illustration of this is the new metallized paperboard for folding boxes, called SilberBoard, that we recently released.”

The market has responded very positively to this new product, hailing it as the first real revolution in the packaging industry for decades.

What makes it so remarkable is that it enables premium brands to get rid of plastics, yet offers consumers glossy, great looking packaging. It also meets environmental requirements from consumers, state regulatory authorities and – at the same time – satisfies industry needs from premium brands in the CPG markets.

“SilberBoard is the result of years of

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Jacky Vanden Ecker, Operations Director

DHL Global Forwarding Belgium

DHL Global Forwarding Belgium, the logistics partner of AR Metallizing, handles their Air and Ocean Freight business on a worldwide level.

Thanks to our global network and dedicated local service, we are able to process even their very big volume shipments efficiently and with the highest care.

We always aim to obtain a win-win situation, by helping AR Metallizing to improve their transportation network and gain competitive advantages.

The strong partnership and the very open communication between our companies are definitely two of the key success points of our collaboration.

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stakeholder’s involvement, extensive R&D and financial investments,” added Bart. “Consumers and authorities favour environmentally friendly packaging, yet consumers’ buying behaviour shows that packaging needs to look great, reflect brand values and remain functional. With our SilberBoard we can offer them an environmentally friendly alternative for their existing plastic packaging.”

In addition to the release and positive reception of SilberBoard, two other recent achievements have even further accelerated the company’s success. In 2015 AR Metallizing became a full subsidiary of the Japanese multinational Nissha. The multinational is listed on the Tokyo stock exchange and is highly regarded for its technological leadership. Nissha’s roots date back to 1929.

Further to this development, AR Metallizing acquired Brazilian-based Malaga Produtos Metalizados, the number one player in the Latin

American region. This brought the total number of the organisation’s manufacturing facilities around the world to four (Belgium, Italy, the US and Brazil), and cemented its position as a trusted global supplier with a local presence.

“The vision we had and still have is that as our clients become more global, we want to be close to them and be able to streamline our supply chain as much as possible. So the acquisition in Brazil gave us a solid and reliable supply chain for our customers in Latin America and it also enables AR Metallizing to move up in the value chain by integrating supply processes and expand and diversify our product portfolio,” Bart explained.

“We also always have a back-up scenario for all plants,” added Jacky. “In Brazil, for instance, we have created the capability to serve customers from Europe if needed. What we also notice is that combining the knowledge of the four different facilities is really helping us to better

AR Metallizing NV

position ourselves, as well as improving our focus on the quality and design of our products, hence we can meet customer needs even better.”

The acquisition also puts AR Metallizing in an even better position to respond to strong current global market demand. “Although oftentimes the perception in Europe is different, we see that especially the American market is very much in favour of sustainable packaging. It is interesting to see for instance how in the American market bottom-up approaches affect the industry. US consumers are advocating strongly for sustainable packaging, which has a major impact on the industry’s behaviour. On the other hand, the industry also starts to understand that ‘going or being green’ is profitable, which is a great opportunity for a company such as AR Metallizing.”

It is clear from speaking to Bart and Jacky that AR Metallizing is a very hands-on and entrepreneurial company, and one that is dedicated to continuous improvement.

“We try to foster internally - throughout the whole company - the spirit to always think ahead and anticipate, by listening, learning and then leading – this is one of my favourite mottos,” said Bart. “If you apply this in the company and towards your clients you are often successful. We also keep a close eye on our competition, pay attention to the trends in the market and as I mentioned, listen to our clients. Of course you also have to undertake the necessary investments and that is what we try to do. Invest in technology, people, and obviously in new products.

“We think that our true competitive edge, is not caused by only having good management strategies, but in the execution thereof. We are continuously focused and result-driven on all levels of our organisation: sales, marketing, purchase, R&D, operations. We are always looking for cost efficiencies and true solutions for our customers.”

Going forward, AR Metallizing’s strategy will be to continue to build on its strengths, with the ambition to always be a better company that can serve the labelling and packaging industry to the best of its ability. “My leadership team is proud that we can steer a company like AR Metallizing, and every day we see the commitment of our people – without them the company would not be the success it is today,” concluded Bart. “We are also proud of our customers, who are also loyal and dedicated to improvement. We are keen to apply the motto of listen, learn and lead to them all, as we believe that such an attitude is necessary to stay at the top globally.”

AR Metallizing NV Services: Global provider of specialty technical coatings for metallized applications

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Hoshizaki Europe Limited

Yoshikazu Fukuma, Managing Director of Hoshizaki Europe Limited, receiving the Grant of Appointment of the Queen’s Award from the Queen’s representative,The Lord Lieutenant of Shropshire, Sir Algernon Heber-Percy

age

The ice

Hoshizaki Europe Limited (Hoshizaki), a leading manufacturer of commercial ice-making equipment, has earned a Queen’s Award for Enterprise in international trade, achieved through investment in manufacturing and the application of three strong business values

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oshizaki produces ice machines, and has acquired a vast experience of the sector and its requirements over the 22 years it has been in operation. During this time the company has continued to grow and to update and improve its facilities, increasing sales and building a strong reputation.

Finance director Haydn Humphreys expanded on the company’s history and development: “Hoshizaki Europe Limited began its operations in Telford in 1994. At that time we had around 20 employees and were producing an average of 20 ice-making machines per day. We now have a 127-strong team and produce, on average, 110 machines per day.” From these humble beginnings the company has evolved and grown, and has based all aspects of the business on a strong set of fundamental values and ideals.

The values that underpin Hoshizaki are three fold. Firstly the company aims to be continuously evolving and developing. By responding to the changes in the culinary requirements of the marketplace it believes it can make a contribution

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to the lives of its customers and to society as a whole. In order to fulfill this aim, Hoshizaki not only manufactures products based on its own original technologies, but is continuously developing new ideas, as well as quality service in support of more comfortable and efficient culinary environments.

Hoshizaki’s second corporate value is the creation of a company that is trusted by society and its employees, and is based on compliance with the law. This means having transparency throughout business, and following clearly defined business practices that allow for debate and discussion. As well as harmonising business activities and the environment, the company has focused on creating an occupational environment that is easy for its staff to work in.

The third corporate value is the Hoshizaki code of conduct. This involves valuing the approach of constantly creating new products, and enabling its staff to try new and unconventional ideas without fear of failure. It also means always considering matters from the perspective of the customer. To facilitate these

values and ideals, Hoshizaki aims to promote an environment where all employees, in every job, are able to work in a friendly and positive atmosphere.

The company has enjoyed a considerable degree of business success by combining these corporate values with updating and improving its manufacturing facilities, as Haydn explained: “In 2014 we were approaching maximum capacity for warehouse space and set about finding additional premises to enable us to expand.

In February 2015, we purchased a property immediately adjacent to our existing premises and began development work to expand our facility. The increased capacity not only gave us the extra warehouse space we required but also enabled us to improve the factory layout and maximise efficiencies to cater for our expanding business.”

Having expanded and improved the warehousing and manufacturing space, Hoshizaki has been able to increase its output and productivity. Today, the company manufacturers 110 ice machines per day, and benefits from being

Declan Walsh, Manufacturing Manager of Hoshizaki Europe Limited, conducting a factory tour and explaining to Sir Algernon Heber-Percy how an ice-making machine operates

part of a much larger organisation. “Hoshizaki Europe Limited, a subsidiary of Hoshizaki Corporation,” Haydn said, “ has a current turnover of £21 million (forecast for 2016) primarily generated from sales of 23,000 icemaking machines (forecast for 2016). The primary purpose of the Telford factory is to supply the European, Middle East, Asian and North American market and we are proud to be recognised for our contribution to EMEA exports.”

It comes as no surprise then, that the quality of Hoshizaki’s products and continuing business performance have been nationally recognised.

Haydn explained: “Having achieved an outstanding performance in exports, with significant yearon-year growth in overseas sales for the years 2012, 2013, 2014 of £13.1m, £14.1m and £16.8m respectively and an outstanding growth in overseas earnings relative to business size and sector, we decided to apply for the Queen’s Award for Enterprise and were delighted to hear that we had been successful in the category of International Trade for 2016.”

Haydn went on to shed some light on the benefits of the award: “Winning this prestigious award has enhanced Hoshizaki’s reputation as

a quality manufacturer and we are extremely proud to be able to apply the Queen’s Award emblem to our ice machines. Our staff have responded enthusiastically to the win, which is a real testament to their hard work and dedication to the company and its products. The anticipated increase in sales as a direct result of receiving this prestigious award will strengthen Hoshizaki’s plans to continue its operations in Telford and we are already seeing a real team effort to meet production targets and satisfy an increased demand for our products.”

Hoshizaki has developed a large international business producing industry-leading products,

and is well-loved and respected by its customers.

With investments in the Telford plant improving capacity and quality as well as receiving the Queen’s Award for Enterprise, the company is going from strength-to-strength, and no doubt has an impressive future ahead of it.

Hoshizaki Europe Limited Products:

Ice-making machines and ice dispensers www.hoshizaki-europe.com

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Anstey Wallpaper Company Ltd

Got you

covered

Benefiting from the broadest machine profile in Europe and backed by design and technical expertise, Anstey Wallpaper Co Ltd has achieved an enviable reputation as one of the world’s most versatile, professional and capable wallcovering printers

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ased in Loughborough, England, Anstey Wallpaper Company Ltd’s (Anstey Wallpaper) history stretches back more than 100 years, during which time the company achieves an enviable global reputation as a versatile and professional wallcovering printer. Not only the largest contract wallcovering printer in the UK, Anstey Wallpaper also has the broadest machine profile in Europe, a strength that is backed by design and technical expertise.

“Anstey Wallpaper is the wallcovering manufacturer of Walker Greenbank PLC, sitting alongside a sister company Standfast and Barracks who print and dye fabrics.

The wallpaper manufacturer, then known as Wallcovering International, which as well as being a manufacturer also had the marketing brands Zoffany and Harlequin, was purchased in 1987. However, wallcovering manufacturing with direct lineage can be traced back through a series of different names for a hundred years or more,” begins Carl Ashby, Business Development Director at Anstey Wallpaper.

“The ambition early on was to transform the wallpaper arm of the business, now renamed Anstey Wallpaper (after the village it was situated in and drew a large proportion of its workforce from), targeting the higher ‘luxury’ end of the market where the vast skills within

the business would focus less on wallcoverings being a commodity product and more on it being a lifestyle decorative purchase, in what was identified at the time as being a rapidly changing consumer led market,” he continues.

Today manufacturing in excess of two million rolls per year through using a variety of different

print processes, substrates and inks, the selfcontained company is constantly looking for new ideas to stay ahead of its competitors.

One way it does this is by researching the latest trends and colours at the London and Paris shows, which results in cutting-edge, on-trend products for its client base. Moreover, Anstey Wallpaper has a specialist technical development department that explores and combines inks, substrates, techniques and technology to ensure the continuous development of new and innovative products from within its own wide range of processes. Additionally, the company’s strong partnerships with suppliers also guarantees it remains fully up to date with

the latest raw materials and works with these suppliers with the goal of creating new ones.

A recent example of the company’s commitment to continuous innovation is the addition of a high tech scattering machine to its factory, which enables tiny beads and particles to be added to a wall-covering; as a result, texture, colour and even light reflection can be added as an accent or simply used to create stunning designs that offer superior durability and adhesion. During 2016 the company also acquired a new digital press, which Carl says provides a number of benefits: “Firstly, unlike conventional printing, digital has no pattern repeat because it doesn’t use cylinders, which by nature have a circumference and therefore a pattern repeat. Therefore a design can theoretically be endless; it reality it tends to lend itself to designs that have a two to three metre repeat, which essentially a wall height. Another benefit is that the minimum order quantity is significantly lower than conventional printing, thus reducing the financial ‘risk’ to our customers

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Anstey Wallpaper Company Ltd

in launching a wallpaper range with all the normal associated costs to it.”

No stranger to investment, the company has a total of 19 individual print machines, which enables it to virtually cover the entire spectrum of printing technologies, which can therefore satisfy any customer demand. The company can also combine these processes to create unique product offerings that won’t be found anywhere else. “We consider ourselves very blessed at Anstey Wallpaper as, to the best of our knowledge, we are globally unique in having every single wallcovering print process, plus a number of variants and hybrids, all under one roof in the heart of the UK,” highlights Carl. “The processes range from 400-year-old traditional wooden block printing through to the uber-modern, very latest digital print machines.

Chronologically taking in surface print, which was the first mechanised way of printing wallpaper, surflex print, flexographic printing, long table screen print, Roto Gravure printing and a state-of-the-art Gravure-Rotary screen hybrid machine that we recently commissioned; this was built in the UK to provide a very specific, unique look.”

He continues: “The beauty of having such flexibility is that we can accommodate most

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customer’s design desires, even if they aren’t prepared to pay the cost of that process, in that we can generally take a more cost-effective process and exploit this to get as close to the look of the suggested process as possible. In fact, we have both a product development and design team whose functionality is to support our customers in this area, which in turn, as you may expect, fosters strong relationships with all of our clients.”

With the wallpaper market growing significantly out of the recession, Anstey Wallpaper aims to continue reaping the benefits of this growth by reacting, adapting and supporting the rapid changes in wallpaper tastes.

However, the company is aware that this growth will not last forever and will also focus on its objective to continue building ever-stronger relationships with customers over the coming years.

Anstey Wallpaper Company Ltd Products: Wall coverings

www.anstey.uk.com

Sukhoi Civil Aircraft Company (SCAC)

High

flyers

Through innovation, quality and compliance to stringent regulations, major Russian aircraft manufacturer Sukhoi Civil Aircraft Company’s (SCAC) is flying high with its family of Sukhoi Superjet 100 (SSJ) planes

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ounded in 2000 with the goal of developing new regional aircraft projects, Sukhoi Civil Aircraft Company (SCAC) focuses on the creation and production of a family of regional planes. In charge of aircraft development, certification and production as well as marketing, sales and aftersales support, the Moscow headquartered company also operates from a production branch in Komsomolk-onAmur as well as business divisions in Uilianovsk, Voronezh and Novosibirsk.

“The main project of SCAC is the production of Sukhoi Superjet 100, a new generation-jet designed and manufactured by SCAC together with Italian-based firm Leonardo-Finmeccanica, which is one of our shareholders alongside Sukhoi Aviation Holding. The SSJ1000 was first presented in September 2007 and the first flight was accomplished in May 2008; the aircraft went onto operate its first commercial flight in 2011. Able to be operated on both short and medium routes, the SSJ100 aircraft are operated by airlines and government agencies in CIS, Europe, the US and Asia; among the company’s largest operators are Aeroflot, Interjet and Gazpromavia,” begins Evgeniy Andrachnikov, Senior Vice-President Commerce at Sukhoi Civil Aircraft Company.

Elaborating on the many milestones undertaken by SCAC to ensure its aircraft comply with rigorous regulations, Evgeniy comments: “In January 2011 the Sukhoi Superjet 100 obtained IAC AR type certificate from the Russian Certification Authority; this certificate confirmed compliance of the SSJ100 with the airworthiness regulations and authorised commercial operations of the aircraft and its safety. Following this, in February 2012 the SSJ 100 (model RRJ-95B) received its Type Certificate from the European Aviation Safety Agency, which recognises that the SSJ 100 aircraft demonstrated compliance with the EASA airworthiness and environmental

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Sukhoi Civil Aircraft Company (SCAC)

Aero Style Founded in 2000, today Aero Style’s main activities consist of the design, construction and installation of interior, galley and entertainment equipment/systems for aircraft. This includes the design and manufacture of equipment and polymeric composite parts, the production of aviation seats and aircraft simulators and the design and manufacture of light aircraft, helicopters and UAV. Its facilities are able to address the entire lifecycle of a product, from design to operation, and thanks to good relationships with global suppliers of materials, instruments and parts, the company provides smooth-running operation and effective quality system at all levels – from design and production process to warranty maintenance.

The manufacturing operation includes a section dedicated to composites - in fact, one of the most important directions of company activity is work with composite materials, which allows decreasing the weight of parts while preserving their strength and durability. Aero Style also has the resources to offer numerically controlled machining, woodworking, metalworking, sewing section, painting section and assembly and electrical assembly.

Over the years since its inception, the company has completed several refurbishment projects for blue chip clients, and at the same time it has mastered new techniques and acquired huge experience in the process of complicated technologies and unique projects.

requirements. This recognition allows the European airlines, as well as those airlines operating in countries that use EASA regulations as a reference standard, to accept and operate the SSJ 100 aircraft. In fact, the SSJ 100 is the first ever Russian passenger large airplane to achieve the EASA CS-25 certification.”

Following further certifications, the company achieved another first for Russia when Russian authorities issued a Supplemental Type Certificate for the SSJ 100 that permits the utilisation of vertical navigation (VNAV) functionality at all stages of flight. This functionality significantly decreases crew workload and ensures compliance with all applicable restrictions. More recently, in December 2015, EASA issued a supplemental type certificate for the SSJ 100, which confirms this type of aircraft can perform flights under area navigation in RNAV 1 and P-RNAV systems. This development was followed

by EASA issuing a supplemental type certificate that confirms the SSJ 100 can operate in CAT IIIa environments.

As the first Russian aircraft to meet the world’s leading airlines’ stringent requirements, the jet has been developed to boast enhanced takeoff and landing performance, high cruising speed and can also be operated in a climate conditions ranging from -54 degrees Celsius to 45 degrees Celsius.

These features make it possible to plan the route network with an element of flexibility, which increases the number of destinations it can travel to; as such, the SSJ 100 can be used on both regional and mainline routes.

Committed to product development, SCAC has three versions of the Sukhoi Superjet 100 within its portfolio: basic, long range and business; it is also working on a stretched version of the aircraft, which will have increased passenger capacity and is due for completion in 2019. SSJ 100/95 Basic and long range has a passenger capacity of 98 in single class configuration and offers customers a superior experience thanks to more comfort for passengers, increased profitability for operators, better support and systems for crews and enhanced environmental performance. The latter of which includes lower fuel burn thanks to improved aerodynamics, fly-by-wire, enhanced performance and a new engine; there are also lower maintenance costs, lower weight-related fees and lower capital costs, all of which result in more than ten per cent cost savings in comparison to SCAC’s competitors.

Meanwhile, the Sukhoi Business Jet is a must for high-flyers who require the freedom to travel anywhere in the world at short notice as well as high-quality facilities and optimum comfort. With more space than any other business jet in its class, the SSJ100 business jet offers more scope for comfort, luxury and facilities as well as interiors tailored around unique preferences. Indeed, by combining the cabin space of an airliner with the luxury of a bespoke Italian interior design, this jet offers a higher level of luxury in its opulent lounge. Increasing this level of luxury is the business jet’s bar, bedroom and washroom, all of which have been produced with the same commitment to delivering superior quality in a relaxing, homely, environment.

Assembled at the company’s modern factory

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Sukhoi Civil Aircraft Company (SCAC)

EPS presently is the exclusive supplier of power distribution units and components for the SUKHOI SUPRJET-100 regional jet.

The history of the program arises from 2002 when the Russian government decided to invest significant budget resources into regional projects for the market’s section which was free of worldwide grants’ presence.

EPS has provided the most advanced components and technological concepts for the project.

SUKHOI SUPERJET-100 became biggest regional carrier of EPS power distribution products in the world. EPS has provided a unique original conception of a 20-channel solid state DC Load Management Unit, which is applicable for pre-serial prototypes and for serial aircraft, too. The universal management and control capabilities of this unit still remain as a reference point in this section of technologies. Key components from EPS are also used in primary power distribution boxes of the aircraft including: relays, sockets, Hall Effect sensors, contactors and other accessories.

Presently the SUKHOI SUPERJET-100 overtakes 100 delivered aircrafts with proven outstanding reliability of EPS power distribution technology.

Such a result is only possible when a supplier actively participates in the design and supports customer requirements and services.

in Komsomolsk-on-Amur, as in company claims, SSJ 100 incorporates the best technology that has been developed by well-reputed leaders in the aviation industry: “These renowned companies include Honeywell, Parker, Liebherr, Safran, Goodrich, Intertechnique and Thales, among others. It is an advanced and cost-effective commercial aircraft built with state-of-the-art technology in aerodynamics, engine and aircraft systems. For example, all models of the SSJ 100 family are equipped with two SaM146 turbofan engines designed specifically for this type of aircraft; the engines are produced by PowerJet, which is a joint venture between Snecma and NPO Saturn.”

Keen to continue enhancing its product’s operation capabilities, the company remains receptive to the feedback it gains from customers and offers additional activities in terms of customisation. For example, following SCAC’s obtaining of the EASA certificate that authorises it to operate SSJ 100 planes on runways down to 30 metres, the company is performing activities to initiate operations in London City airport, one of CityJet’s key locations, by December 2017; in line with this development, the company will undertake further improvement and performance of the aircraft via installation of horizontal winglets by 2018.

This mode will be guaranteed by wing-flap system modernisation and FMS and avionics improvement, which will enable the CityJet fleet of SSJ 100’s to fit in the short London city runway; flight tests are due to begin in the summer of 2017.

With three types of innovative aircraft already in its portfolio, SCAC is keen to continue strengthening its foothold in the aircraft market with new products, as Mr. Andrachnikov highlights: “We recently attended the Farnborough airshow 2016, where SCAC introduced the concept of a new aircraft designed to fly professional sports teams: Sportjet by Sukhoi.”

A mock-up of SportJet by Sukhoi was exposed in Rio during Olympics in August.

The concept of SportJet is based on the expertise and technology of Sukhoi Superjet 100, enhanced by innovative medical and IT solutions developed in co-operation with sports physicians, experts and managers. SportJet by Sukhoi is based on scientific and practical research in the field of sports, such as the impact of flights, jet lag, hypoxia, dehydration, stress on the body and aerophobia that affect professional athletes from various sports.

Among the potential customers the company sees national sports federations, professional sports clubs, individuals and businesses. SportJet by Sukhoi will provide custom aircraft versions for professional teams in such sports as football, hockey, basketball and rugby, as well as a solution for customers from business aviation, emphasising its ties with the sport and paying particular attention to health issues. The aircraft is easily customisable based on the client’s needs.

Having set the foundations for further growth in locations such as Europe and also China, where the company going to open an office by the end of this year with the goal of taking one tenth of the market, the future looks full of opportunities for SCAC as it not only focuses on strengthening its foothold in existing areas but also seeks out untapped markets such as Africa.

Sukhoi Civil Aircraft Company (SCAC) Products: Regional planes

www.scac.ru/en

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Bristow Group

machine

Man and

Bristow Group is the leading provider of industrial aviation services offering exceptional transportation, search and rescue (SAR) and aircraft support services, including helicopter maintenance and training, to government and civil organisations worldwide

W

ith headquarters in Houston, Texas, Bristow has major operations in the North Sea, Nigeria, the US Gulf of Mexico, and in most of the other major offshore oil and gas producing regions of the world, including Australia, Brazil, Canada, Russia and Trinidad.

Bristow also provides SAR services to the private sector in Australia, Canada, Guyana, Norway, Russia and Trinidad, and to the public sector for all of the UK on behalf of the Maritime and Coastguard Agency.

The UK division, Bristow Helicopters Ltd, has served the offshore oil transport industry in the UK for over 50 years. Since 1971, Bristow Helicopters has flown more than 60,000 SAR operational hours and conducted over 15,000 SAR missions, during which the company’s crews and helicopters have rescued more than 7000 people.

In 2013 Bristow won the UK Government national contract to deliver SAR operations on behalf of the Maritime and Coastguard Agency

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(MCA). Seven of ten strategically located bases have taken over the helicopter SAR responsibility from the military in a phased approach throughout 2015 and 2016. The remaining three, two of which are already operated by Bristow, are set to become part of the new contract in 2017.

Given the sterling reputation for excellence that Bristow has earned in the marketplace over its years of existence, it is no surprise to learn that the company has always worked closely with only the best suppliers of helicopter technology.

For example, it has been doing business with Sikorsky (a Lockheed Martin Company) for 40 years, and as recently as July 2016 the companies signed a ten-year agreement providing Bristow’s S-92 fleet with extended support for its aftermarket material needs. Sikorsky’s Total Assurance Program provides Bristow continued aftermarket support to operate its S-92 fleet within a known budget, reducing the risk of unplanned costs.

Bristow has been a loyal operator of the S-92

helicopter, which perform at an average air speed of 145 knots (166 mph) and have the endurance to perform for more than four hours without refuelling. They are outfitted with state-of-the-art technology including: • High definition forward looking infra-red (FLIR) and thermal image camera technology • Night vision goggle (NVG) technology including glass cockpit • Icing protection system • Twin hoist • Comprehensive medical suite Overall, the Bristow fleet features more than 160 Sikorsky aircraft, of which more than 75 are S-92 helicopters. These are operated in Europe Caspian, Africa, Asia Pacific and the Americas.

Bristow Helicopters Ltd. currently operates 14 S-92 helicopters on behalf of the UK Maritime and Coastguard Agency for SAR. In the first year of UK SAR operations, beginning April 1, 2015, Bristow successfully completed 1149 missions utilising S-92 helicopters. In fact, such has been the success that Bristow has seen through its operations using the S-92 that at the same event as the support agreement highlighted previously was signed (the Farnborough Air Show) Sikorsky

recognised Bristow Helicopters Limited and the UK Maritime and Coastguard Agency for excellence in lifesaving achievement with the S-92 helicopter.

It is clear from recognition such as this, that Bristow Helicopters delivers vital and exemplary services in SAR, and in 2016 it has celebrated two significant anniversaries in this area – it is the third year it has delivered the Gap SAR contract from Sumburgh and Stornoway in Northern Scotland on behalf of the Maritime and Coastguard Agency, and the first successful year of SAR in Lydd, from the base at London Ashford Airport. The HM Coastguard service became operational at Lydd on 14 August 2015 and statistics for the base’s first year show that the crew at Lydd responded to over 180 taskings from the Aeronautical Rescue Co-ordination Centre (ARCC).

At the same time as Bristow Helicopters has been undertaking SAR services in the UK, the Group has been working across the world, and during the recent Louisiana floods in the US in mid-August, Bristow supported helicopter rescue efforts for affected residents. Working in close co-ordination with the Office of Homeland

DART Aerospace

With over 700STCs, 5000 parts and 3500 tools for civil and military rotorcraft, DART Aerospace has supported the Bristow Group’s fleet requirements and evolution over the years. DART offers many products that facilitate Bristow’s offshore operations, helping them save weight and reduce costs while maintaining their commitment to safety. DART’s patented emergency floats with integrated life rafts as well as its sturdy and corrosion resistant landing gear are some of the key products that have helped the company accomplish their missions. DART has also supplied a wide assortment of quality rotorcraft tools for Bristow’s AW139 bases resulting in cost savings.

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Bristow Group

GE Aviation

GE is proud to commemorate its ten-year relationship with Bristow, providing reliable CT7 power for the global fleet of S-92 and AW189, including all UK SAR helicopters.

The CT7 has provided commercial airline reliability, delivering amazing time on wing for a Turboshaft engine. World-class response and support will always remain the company’s collective calling card – every mission along the way.

Security and Emergency Preparedness for Livingston Parish, Bristow teams based at Galliano and New Iberia quickly mobilised the company’s response to provide critical care to those in need.

Utilising an advanced Leonardo SAR AW139, a Sikorsky S-76C++ and a Bell 407 aircraft, Bristow crews carried out several missions over the two days to provide critical assistance to displaced residents and their pets. The emergency calls and SAR taskings were communicated to Bristow’s SAR dispatch, which were triaged for severity and relayed to rescue crews.

Throughout the rescue missions, the crews performed dynamic risk assessments as the situations unfolded. Due to their extensive experience with SAR, the crews are well versed in performing these risk assessments.

“Our employees are on the front lines, saving lives and making a difference,” commented Bristow’s Americas Region Search and Rescue (SAR) Manager David Jacob. “I couldn’t be more proud of this team in completing our rescue taskings without hesitation or question, especially considering that many of our employees were also affected by flooding from this storm.”

The operations undertaken around the world

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by Bristow display the true professionalism, teamwork and unwavering dedication to the lifesaving mission that each of its employees possesses. They also show how these staff work in harmony with the helicopter technology at their disposal – for example Bristow’s SAR AW139 helicopter is equipped with state-of-theart equipment, including a 700Mhz radio that allows for communication with the multiagency responders, mission management capabilities, external rescue hoist system and critical care medical equipment. Onboard the aircraft are two pilots, hoist operator, rescue swimmer and flight paramedic. This perfect unification of man and machine has saved thousands of lives across the world since Bristow was founded, and going forward the company looks set to continue in its critical operations, changing lives and making a difference to those in need of rescue.

Bristow Group Services: Industrial aviation services

www.bristowgroup.com

The Sertec Group Ltd

The right

components With more than five decades of industry experience, The Sertec Group has established itself as a specialist manufacturer of automotive components in aluminium and steel

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Head office, Wincaster House

T

he Sertec Group Ltd (Sertec) was founded in 1962 as an engineering business, predominately in the manufacture of press tooling for the automotive industry and has since grown to represent a major force within the UK manufacturing industry. “In 54 years, Sertec has witnessed dramatic changes in the UK automotive sector with a clear objective to grow and prosper. The company’s strong management team and commitment to excellence in everything it does has seen it not only survive where others have fallen, but rise to become the largest independently owned manufacturer of its kind in the UK,” explains Group Managing Director, Dave Steggles. “Quality manufacturing has ensured the continued success of the business and through a policy of continued improvement, investment and acquisition, Sertec is now responsible for over 1500 employees across its five manufacturing sites that deliver sales of over £200 million.”

Sertec operates two factories in Coleshill, one in each of Aston, Saltley and Tyseley in Birmingham as well as a tooling business in Guangdong Province, China. Across these sites the company is specialised in the delivery of

products ranging from stamped components in both steel and aluminium; complex assemblies utilising robotic and manual welding; as well as employing the latest automated riveting technologies required for aluminium structural assemblies.

Sertec also supplies tubular assemblies including exhaust bright trim and wire formed products; with customers currently including world leading names such as Jaguar Land Rover, Ford, Scania, Tenneco, Denso, UYS, Unipart, Arvin Meritor, TRW, ZF Lemforder and GKN. By working with several industry-leaders in the automotive sector, the company has established a strong market presence with its products reaching markets within China, the USA, Mexico, Germany, Sweden, Holland, France, Belgium and Brazil. The business has enjoyed significant growth over the last eight years with sales rising from £40 million in 2008 to £200 million today.

The trusted and long-standing relationships between Sertec and its customers have been founded upon the company’s dedication to working in close collaboration with them to ensure that it delivers the best solution to meet every component’s unique requirements. Once a solution has been agreed on, Sertec remains on hand to provide assistance throughout the

Sertec’s new logistic centre

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e

The Sertec Group Ltd

£16 Million investment in a brand new Stampings facility at Sertec’s Birmingham factory

entire development of the final product. “In co-operation with our main customers, Sertec has been successful in innovating and enhancing the use of aluminium to deliver a broad base of ‘lightweight structures’. We intend to develop these products further with significant investment and engineering resources focused purely in this area. Over the coming years we will also continue to work to further develop our understanding and knowledge of alternative materials,” Dave says. “Sertec manages a dedicated design team that supports our customers with design feasibility right through from initial design to full design testing and prototype supply. Our commercial and logistics team also operate established teams to support any customer aftermarket requirements.”

To allow Sertec to continue to better serve its customers, it was announced during February this year that the company had secured a £20 million funding package from the Business Growth Fund (BGF) and Lloyds Bank Commercial Banking to support the company’s management team in its continuing expansion plans for the business. Sertec currently produces over three million components per week across its five operating sites within Birmingham, while

new BGF funding will allow the business to accelerate its production and growth strategy.

The funding comes in addition to £20 million in working capital that was invested into Sertec by Lloyds Bank in August 2015.

Indeed, Sertec invested heavily across all of its operating centres during 2015, through the implementation of new robotics, presses and site upgrades. During 2016 the company will complete a brand new £16 million press shop at its Coleshill factory, where 13 new transfer and progression presses will be fully operational within the next 12 months. The investment

by BGF and Lloyds Bank will facilitate Sertec’s continued expansion to support Jaguar Land Rover’s exciting development of new vehicles such as last year’s launch of Discovery Sport and Jaguar XE and this year’s arrival of Jaguar’s new crossover F-Pace and the convertible version of the record breaking Range Rover Evoque.

“Partnering with both the BGF and Lloyds is critical to the next steps the business needs to develop not only our product range, but also our international footprint,” Dave observes.

“Following a full review of our UK plants, the board decided to not only focus our stamping facility in one UK facility, but to also replace

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Head office assembly hall

predominately manual capacity with the latest progression and transfer automated capacity. This will both improve the productivity of the group as a whole as well as to future proof the site.”

Additional to allowing Sertec to invest in its plant and equipment, this latest deal also supports the company’s on-going programme of restructuring. The reshaping of the business began as long ago as 2006 with long term plans in mind; and as part of this latest investment, Sertec’s founding Mosedale family have retired from the business, with a strong executive management team comprised of Grant Adams (CEO), Dave Steggles (Managing Director) and Finance Director Martyn Hughes taking over the reins of the business. Across this team there exists over 83 combined years of experience in working at Sertec and a passion that will ensure that they will continue to lead the company for years to come. “Bringing BGF on board complements the strong partnership we have enjoyed with Lloyds Bank for over 50 years and allows us additional flexibility for our ambitious growth plans. The combination provides a well-balanced source of support and funding, both now and in the future,” Group CEO Grant Adams says. “Whilst we share important plans with Jaguar Land Rover, we must also expand

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our customer base and extend our geographical reach into Europe. It is testament to our potential that this is The Business Growth Fund’s largest single investment in the automotive industry to date.”

Since securing the latest of a series of financial investments into the business, Sertec has moved to increase its manufacturing footprint.

For example, during May 2016 the company announced an agreement to lease a brand new Logistics facility at The Hams Hall Estate, just a mile from its head office as part of its ongoing expansion plans. Indeed, as Sertec continues to grow, the inclusion of this new facility will allow the company’s existing storage areas to be reallocated to the production of finished goods. “Our Group strategy has always been to attract more customers and a more diverse range of products to manufacture. Furthermore, export markets are becoming more and more important to us and we must improve our sales to both existing and potentially new customers overseas,” Dave details. “Given such targets, this exciting new development will allow us to not only demonstrate greater manufacturing capacity across our factories, but now we have added an outstanding stand alone distribution centre to our business. As we invest in our

The Sertec Group Ltd

Robotic weld technologies

future, such developments are essential to accelerating growth whilst continuing our drive for performance excellence.”

But the very latest initiative is all about the people Sertec employs. With the continuing success locally to Sertec of Jaguar Land Rover and the automotive industry in general, the pressure on the UK Midlands supply chain to find new skilled labour continues to be an issue.

The Sertec Group’s investment in bricks and mortar, plant and equipment has certainly increased manufacturing capacity. But to sustain such growth, the business is now investing in its people with the launch of the Sertec Learning Academy.

Training has always been a part of building an effective and efficient workforce. But with the launch of the Academy, Sertec can now take new, unskilled people, give them a world class induction and train them before a single day’s work is done.

Based at Sertec’s Wincaster House headquarters, the Learning Academy covers all aspects of the manufacturing processes involved in the supply of automotive components, not only for new starters but for existing employees too.

CEO Grant Adams said: “This is only just the beginning. The possibilities are endless in our efforts to up-skill our workforce and with our current team of 1500 people increasing by a further 100 workers over the next 12 months, the Academy is an essential development in the future of our business.”

Quality and performance excellence is the be all and end all in automotive manufacturing and Sertec has instilled a mentality and a structure

to reflect that. This is achieved through the implementation of quality procedures that are fully compliant with all applicable industry standards used throughout the Sertec Group of companies. Shared database facilities and group wide functions such as advanced quality planning (AQP) and supplier development ensure that the quality of products and services is of the highest quality of all times.

Jaguar Land Rover has in recent years awarded Sertec its highest accolade relating to supplier quality and manufacturing, over and above more than 1200 JLR suppliers worldwide.

The combination of the company’s modern production facilities, dedicated staff and leading quality management systems have made Sertec a trusted partner to some of the automotive industries most demanding clients and will further strengthen the business as it continues through the second half of 2016 and beyond.

“Market conditions generally remain positive for us at present and we expect the sector to remain strong throughout 2016 as we launch several new products,” Dave concludes. “Our main competitive edge remains as it always has been on our people and our ability to adapt to market and technological changes. This is added to class leading quality and delivery performance.”

Sertec Group Ltd Products: Specialist manufacturer of components in steel and aluminium for the automotive sector

www.sertec.co.uk

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Servopresse Srl

Aid to

press

Sertec’s se supplieler cted

With a history dating back over more than 45 years to when the company was founded with the aim of designing and producing equipment for process coil material for presses, Servopresse has developed a reputation as one of Europe’s leading companies in this sector

S

ervopresse products are found in shears, forming machines and machines that use sheet metal coils across several industry sectors.

The company was founded in 1970 and today continues to operate as a mid-sized privately managed organisation, with around 40 employees and partners operating in its factories in Milan and Nice covering a combined space of 5000 sq. metres. Throughout its history Servopresse has remained at the forefront of developing markets, new customer requirements and ongoing technology trends, which the company is able to respond to quickly, owing to its experience as a family owned business.

Indeed, since Silvano and Umberto Cecchi first established the firm, Servopresse has sold in excess of 5000 coil lines to customers worldwide.

The business is in its second generation and is currently under the successful guidance of Dario, Lara and Paolo Cecchi, operating as technical, commercial and financial managers respectively.

“The name Servopresse comes from a play on words, with ‘servo’ in the Italian language meaning aid or servant, while ‘presse’ simply means press. Therefore the name Servopresse Heavy coil

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Lara Cecchi, Commercial Manager, Servopresse

literally translates to ‘aid to press’. My mother conceived this name 46 years ago, when the company was founded and the brand was later officially filed in 1975,” reveals Commercial Manager, Lara Cecchi. “In recent years this name has been increasingly useful to us, because the development of technology in building presses with servomotors, has resulted in greater visibility for our company. Since we obviously own the trademarks and domains for Servopresse that are recorded for our organisation, this is something that does somewhat ‘stick in the throat’ of several press manufacturers who would like to have the exclusivity of this major brand. It is a fact that we received some interesting takeover offers in recent years, especially from manufacturers based in Asian countries wishing to expand their activities in Europe. This would give them a major advantage over their competitors since they would then automatically have a point of distribution in Europe, however Servopresse is a family company and the progress that we achieved in the last few years has given us a lot of confidence. Therefore, we are keen to continue to push further in this area, by endeavouring to build even more advanced lines in the future.”

Around 95 per cent of the components produced by Servopresse are exported to clients outside of Italy through a network of technically qualified distributors, which are able to offer customers full installation services and

aftersales support. This has allowed Servopresse to gain a reputation as a trusted supplier to leading OEMs including Sertec – an important equipment supplier for Jaguar-Land Rover. The company’s production range covers all coils up to a maximum capacity of 20 tons, widths of up to 2000mm and thicknesses of up to 20mm.

Servopresse can build single machines, compact lines and special lines comprising: Decoilers: single or double, with or without motor, and hydraulic self-centring expansion.

Straighteners: normal or feeding straighteners, comprising a cast iron drafting head and hardened and ground steel straightening rolls.

Electronic roll feeders: easy to use and suitable for automated lines.

Traditional lines: these feature decoilers and straighteners to be used with an independent feeder.

Compact lines: these are composed of integrated decoilers and feeder straighteners.

Special lines: to satisfy most sophisticated working requirements such as zigzag feeding lines; straightener cradles; bar feeders; complete cutting lines; micro perforation and embossing coil lines as well as automatic multi-disc cutting lines from coil.

• • • • • •

Heavy duty line

e

Traditional coil loop line

The company’s comprehensive product portfolio is supported by its flexible management structure and ‘made-to-measure’ manufacturing processes that have allowed Servopresse to remain both buoyant and competitive in a challenging market. Rather than operating as a simple assembler, the company manufactures around 85 per cent of the components it uses in-house, which enables it to satisfy even the most sophisticated, diverse and complex manufacturing requirements.

“Through a period of global financial downturn that has affected most of the world across almost all sectors, we have emerged stronger with a close-on threefold increase in production and our forward order book is full up to mid-2017,” Lara exclaims. “For example, we have seen an increasing demand for machines that can process new, high-strength materials or aluminium. It is important for our customers that our machines are very capable and increasingly automated.

Most of our customers are big companies

wrestling with shortages in skilled operators, meaning that machines need to be automated to support their operations. In the last year, our production has changed from semi-automatic to fully automatic line production and we have therefore developed new automatic threading adjustment systems for coil feeding equipment which enables us to offer complete decoiling, feeding and straightening lines able to automate the set-up phase of these machines.”

During the next 12 months and beyond, Servopresse will continue to provide marketleading solutions to its clients while managing the demands of a volatile global market. Its international customer base has given the company a diverse range of clients and a strong order book that will help the business to further develop its global reputation and win new orders over the coming years. “The UK is the most important market for us right now and we deliver to a lot of customers there. We are honoured and proud to be a supplier to one of our best customers, Sertec where in recent years, we have delivered almost 15 large lines ranging from 1000mm to 1600mm/10-15 ton coil width. Sertec operates multi-production runs so automation is very important for the business, meaning that it wanted compact lines that are very small and space saving. Line safety is also a key prerequisite for us and we fix protective barriers as an integral part of the machine and not as an add-on,” Lara concludes. “Servopresse also has customers in Poland, Hungary and Scandinavia as well as Italy. It has also delivered lines to customers in the US, Mexico and Brazil and is currently in the process of delivering a machine to a rollforming manufacturer in India, with a further project for a customer in Russia.

We view the Italian and global markets market as a challenge but also, more importantly, an opportunity.”

Servopresse Srl Coil and associated equipment specialist

www.servopresse.com

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Collins and Hayes Furniture Limited

Sitting

pretty

S

ituated on the coast in the South East of England and steeped in history, Collins and Hayes has been successfully designing, developing and manufacturing upholstered furniture of the highest quality for over 140 years. It takes pride in offering its customers a wide choice of beautifully designed and styled products.

Collins and Hayes’ upholstery has always

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Collins and Hayes is a designer and maker of bespoke furniture, and going forward is focusing on efficiency, modernisation, and increasing its reputation

been handmade. Over the years the company has earned an enviable reputation for elegantly designed and well crafted furniture, based on skilled and knowledgeable craftsmen with a deep understanding of materials and construction techniques. The large collection of fabrics and

leathers are specifically selected and sourced from all around the world in order to enhance and complement its furniture.

A great deal of effort and experience goes into crafting Collins and Hayes products, so it comes as no surprise that the company has

recently received a number of awards. Managing director Matt O’Flynn explained: “The first recognition we received this year was at a Birmingham trade show in January where we won an award for best design. Then in August we won the Interiors Monthly award for the best UK furniture manufacturer of 2016. This award was voted for by the readership of Interiors Monthly, which is made up of retailers and the supply chain - and this represents a really broad spectrum of professionals from the industry including importers, wholesalers, manufactures, retailers and traders. So the award really demonstrates the impact we had in the market last year, and it’s something we plan to build on.”

The awards are a clear recognition of what Collins and Hayes is striving to achieve - to produce the best quality for its customer.

All Collins and Hayes models employ close attention to detail in their construction. The handcrafted frames are engineered to slot together, then glued and screwed by highly skilled craftsmen and come with a lifetime guarantee. The furniture is also bespoke. It can be customised to fit a specific space and tailored to suit requirements, including increasing or decreasing the width of the sofas.

In addition to the extensive focus on customer preferences and material quality, there is a range of new product designs that are likely to prove popular throughout the rest of 2016 and into 2017. Several of these deserve special note. There is the Dalston, which is new for Autumn 2016 and features feather seat and pillow cushions inside a tailored natural fibre covered frame, which is designed to provide a comfortable space to relax. Then there is the

Shelby, a refined, architecturally designed corner unit that provides large seating capacity and is available in modular combinations, which the company has designed to be a stylish option.

There have been a number of improvements to the business by Collins and Hayes, and this is something that Matt elaborated on: “We have continued to bring new products to market, and improve the quality of the merchandise we are making. But we have also advanced the manufacturing side of the business. Internally a great deal has changed. We have reduced the amount of space we operate out of in order to increase efficiency and to become more customer orientated. The result of all of this is that we now have a higher capacity, and have been able to focus on reducing costs and making the product even more appealing for the market.”

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Collins and Hayes Furniture Limited

Collins and Hayes has made other improvements to its facilities, as Matt explained: “We have completely refurbished our wood mill with a clean supply of electricity and a new extraction system. We are investing in new machinery, and we have also upgraded our IT capability with a new ERP system. This has provided us with a much more robust and modern platform and has made the whole order processing more slick. One example is that we have now electronic order acknowledgments and invoices.”

It is clear that Collins and Hayes is embracing

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the future, finding new ways to provide its traditional quality with modern systems, processes and equipment.

The company is focused on increasing its reputation both domestically and internationally.

One of the methods it is employing to achieve this is by attending trade shows and exhibitions, and Matt elaborated on this: “The Long Point open trade show, based in Long Eaton, is actually the centre of excellence for furniture manufacturing. With around 40 or so exhibitors it is a significant exhibition, and provides us with the space to show off what we have to offer,

which adds value to our business.” Internationally the company is looking to increase its exports, and Matt gave more details: “We are looking to take a stand at the Milan furniture show, which will provide us with an opportunity to promote our fine range of furniture internationally.”

The company has a number of plans for the future, and these include a complete revamp of the website and attending more expos. While Collins and Hayes continues to focus on making quality furniture that provides comfort and style, the company is determined to continue its forward momentum. Its ethos is a commitment to finding new innovative approaches to production, marketing and materials. Its aim is to create products it genuinely believes in, and without a doubt it will go on to collect many more awards in the future, and attract many more customers.

Collins and Hayes Furniture Limited Products: Bespoke furniture

collinsandhayes.co.uk

Broadwater Mouldings Ltd

Breaking the

mould Ongoing investments in upgraded technology will ensure leading composite manufacturer Broadwater Mouldings Ltd develops a strong global presence in both new and existing markets

E

stablished in 1973, Broadwater Mouldings Ltd is a subsidiary of the Betts Group and operates from a modern, purpose built manufacturing facility in close proximity to Beccles, Suffolk, where it manufactures fibre reinforced plastics (FRP) for a range of industries. “Essentially we are a service provider as everything we manufacture is custom-moulded and directly advised by our customers; they come to us with an idea for a product, whether from a design or a drawing, and we manufacture exactly what they want before shipping it out to them when they want it. We primarily work in THE medical, automotive and industrial fields for customers such as Philips Medical, JCB, McLaren

Automotive and Lotus,” begins James Cushing, Sales Manager at Broadwater Mouldings Ltd. An innovative British design engineering and composites manufacturer, Broadwater Mouldings specialises in moulding high quality fibre reinforced plastics (FRP) and fabricating finished assembled FRP components for a diverse range of customers in the UK, Europe and across the globe. To ensure the company can provide the most suitable solution to customers, James says Broadwater Mouldings offers a wide range of moulding techniques: “We manufacture through a variety of different technologies; there is Hand Layup, for smaller parts and smaller volumes, and Spray Layup, which is for larger parts; we manufacture campervan panels with this

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technology. There is also Resin Transfer Moulding (RTM), which involves the resin, gel coat and glass fibre mat being put in a closed mould before the resin is drawn out by a vacuum to create the part, and Low Pressure Press Moulding (LPPM), which although the tooling is more expensive can create higher volume parts leading to the actual product being less expensive per piece.”

Closed mould processes such as LPPM, RTM and RTML (Resin Transfer Moulding-Light) produce a smooth semi-cosmetic B surface that is preferred by many customers. Similar in the sense that they all produce a composite of polymer matrix and glass fibres, Hand Layup, Spray Layup, LPPM, RTM and RTML all typically use polyester, which can be formulated while in a liquid state to give specific properties for particular applications; these include reduced

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shrinkage and flame retardancy. During the moulding process, the resin is converted from a liquid into a solid polymer, encapsulating the glass fibres to form a composite structure. Post moulding operations include trimming (either manual or robotic), drilling, assembly and, in some cases, painting.

With every aspect of the design and manufacturing process completed in-house, the quality-conscious Broadwater Mouldings ensures it has full control and traceability on all products that leave its site. “Our quality and expertise is second to none in the industry,” says James. “We have a very experienced workforce, with many employees working with us for more than 20 years; this level of experience means we know exactly what we are doing. Moreover, everything from design to tool making, to actually designing the jigs and pallets that the products are dispatched on is done in-house. We work to ISO 9001, so if we start from the glass fibre cut, through the laminating process, to final checks and dispatch we follow a six-part process to sign off as we go before the product is sent out. This commitment to quality ensures full traceability over every single thing that goes out the door.”

As one of the leading fibreglass composite manufacturers in the UK, Broadwater Mouldings has remained in demand in both the UK, Europe and throughout the world. However, to further strengthen its foothold in the market, the company continuously invests in its facilities and announced the completion of an upgrade to its robotic trimming department in July 2016.

This investment will allow the trimming of over 70 per cent of its FRP mouldings to be done by robots, which will enable the company to grow in both new and existing markets, as

Broadwater Mouldings Ltd

James confirms: “With 70 to 75 per cent of our parts trimmed by robots, we will create a more accurate trim and lessen the cost for our customers. This development comes at a time when we are looking to grow again by targeting specific markets such as the automotive market, which will be looking for lighter weight parts within cars and ready production cars over the coming years.

“We anticipate that by 2025 manufacturers

will start to develop lighter weight parts; in response to this we are involved in R&D on new materials to diversify away from traditional GRP markets and potentially provide parts to customers who haven’t used GRP in the past and would traditionally use metal.”

With this new upgrade increasing flexibility and enhancing reliability and accuracy, Broadwater Mouldings is at the forefront of FRP manufacture and assembly in the UK

and is ready to take on new opportunities on a global scale.

Broadwater Mouldings Ltd Products: High quality fibre reinforced plastics (FRP) and finished assembled FRP components

www.broadwater.co.uk

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Mecaplast Group

Moving

forward

Reaping the benefits of a surge in growth in the UK automotive industry, Mecaplast UK Ltd has doubled its size and turnover in the past two years

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ecaplast Group is a worldwide Tier 1 Automotive parts supplier with a revenue of 734 million euros and locations in 18 countries across the globe. The 6000 strong Mecaplast has evolved over the last 60 years to be at the forefront of automotive equipment production activities. “Mecaplast was founded in 1955 in Monaco by Charles Manni and is today a European leader in plastic injection moulded parts for automotive market applications. We design and develop parts and complete systems for vehicle engines and body applications and support our strategic clients as they go global,” begins David Cann, Plant Director at Mecaplast UK. He continues: “The parts we produce are split into three main categories, engine, interior and exterior, each of which accounts for approximately one third of the company’s turnover. Examples of engine parts are associated with air, water and thermal

management, valves and housings, while interior parts include pillar trims, garnishes, cockpit and trunk parts; the exterior portfolio includes body side mouldings, painted parts and functional black covers and under trays.”

Boasting superior expertise and facilities when it comes to design and development resources, test, validation and measurement resources and calculation resources, the group is able to develop wholly compliant products that offer safety, comfort and performance to customers. Indeed, for testing of products alone, Mecaplast has nine testing and validation centres, additionally, for painting and decoration operations it has paint application facilities on three sites across the globe as well as one external finish development centre.

Furthermore, its human resources complement the technical resources, with over 300 engineers and technicians able to take care of projects, from development through to product delivery, on a local basis.

“

Mecaplast is investing in new technology linked to the light-weighting of parts to satisfy the evermore stringent emission legislations as well as increased mileage needs from both fossil fuel and battery powered vehicle solutions

Aim to Recycle Having achieved rapid growth when it comes to Mecaplast’s number of employees and annual sales revenue over the last half century, the company made the strategic decision to divide its sales revenue into two fields of expertise during 2002 and 2003 following a surge in success during this period. The two business segments were Mecaplast’s car body skills centre, which focuses on weight saving, CO2

reduction, acoustic, cosiness, safety and quality, and its engine skills centre, which focuses on CO2 reduction, weight saving, soundproofing and performance and reliability. In fact, from 2000 until 2002, the company grew to 580 million euros; this progressed further, with the company achieving revenues of 759 million euros (736 million euros for the automotive industry) by 2007.

Aim to Recycle work closely with a wide range of plastics manufacturers. Aim to Recycle specialise in automotive plastics and can purchase clean segregated materials as well as offering solutions for mixed or contaminated waste materials. Aim has serviced Mecaplast for over 13 years and in that time had great success improving recycling rates and aiding impressive waste minimisation services. Aim is able to provide specialist equipment to ensure customers maximise recycling rates.

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Mecaplast Group

Discussing the reasons behind the company’s continued success, David comments: “Mecaplast has grown over the years via acquisition and organic growth; we also have a diverse client base and a client-centric business unit organisation that allows strategic product focus as well as for emphasis on innovation. Alongside the international footprint development, these customer focused initiatives have translated into a high level of business awards; this demonstrates the confidence of Mecaplast clients in the group and its strategy.

“As a tier one supplier, Mecaplast understands the needs of the industry to keep moving forward; to stand still is to fall behind in our world,” continues David. “With this mindset, driving continuous improvement in all areas of our business, we strive every day to be competitive, with a high level of

quality performance that is achieved in a safe environment from our workforce. These strengths perform as the cornerstones for our sustainability. We operate to a clear set of company values that are shared between all Mecaplast employees that have been designed to direct company activity in a positive way.”

Alongside these developments, the company also set upon a 3000 m2 factory extension project and invested in four new injection moulding machines in 2013 in response to an increase in contracts leading up to 2016; the company also expanded its workforce at its site in Peterlee, County Durham, to ensure it could handle the increased demands in production.

“Since 2013 the UK site in Peterlee has grown from a workforce of 84 people to 145 due to a factory extension project which saw turnover increase by more than 100 per cent,”

highlights David. Not a company to rest on its laurels despite this major success, Mecaplast has continued this long tradition of improvement with investments in renewing ageing equipment and the adoption of new technologies to meet changing market demands and customer expectations, as David adds: “Mecaplast is investing in new technology linked to the light-weighting of parts to satisfy the evermore stringent emission legislations as well as increased mileage needs from both fossil fuel and battery powered vehicle solutions.”

The company has also invested more than £3.5 million in 2016 in a further four injection moulding machines and a partnership with Access Training to enhance the skills of its growing management team after securing a major contract with Jaguar Land Rover. “In 2017, the workload will increase further as a new development project with new client, Jaguar Land Rover, begins production.

“Staff development is paramount to us staying competitive and remaining a leader in the automotive field; we need to be at the top of our game at all times. A pre-requisite to this is the continued improvement of our technical capabilities and process efficiencies through the development of our teams,” notes David.

“Meanwhile, when it comes to Mecaplast’s investments, we do so with a firm eye on the newest technology from the major known brands of injection moulding machine builders and suppliers and will thus strive to bring this technology to our clients through co-operative development programmes. Through these collaborations we hope to serve our clients with the newest innovations in terms of quality, cost and delivery.

“We do not stand still and are already engaged with our clients to understand their needs and strategies for new and potential projects. We then make our internal plans and discuss our own strategies in line with our customers to ensure we are ready and agile enough to support the unique demands of customers, whatever they may be,” concludes David.

Mecaplast Group Products: Automotive parts and complete systems for vehicle bodies and engines

www.mecaplast.com

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Sumgait Technologies Park

Building the

future

Sumgait Technologies Park is an extremely diversified place, where the latest technology breakthroughs are met with innovative solutions and backed with vast experience. It’s a unique complex with large scale production facilities that contributes to the sustainable growth of the Azerbaijan economy

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he President of Azerbaijan Republik Ilham Aliyev launched Sumgait Technologies Park on 22nd December in 2009. It is a unique project in the region and is able to satisfy the requirements of the domestic market as well as the foreign market. The establishment of such an industrial centre in Sumgait City is not only a boost in economic development of Azerbaijan, but also is a restoration of the historical traditions of Sumgait founded as an industrial centre in the Caucasus.

More than 4500 people are currently employed in the production and construction-installation fields of the organisation. After the launch of all planned plants, it is expected that the facility will employ around 10,000 people. All production facilities are equipped with the best technological equipment manufactured in Europe where raw materials are imported from the leading producers. All its factories are equipped with the latest laboratories manufactured predominantly in Western Europe and accredited to AZS ISO/IEC 17025-2009 standard.

New enterprises are established on the basis

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of equipment based on high standards and up-todate technologies. Devices and equipment used in the production process are products of the leading manufacturers of the world. Therefore, finished products are of high quality. Currently, 25,000 kinds of power and communication cables, specially designated plastic pipes and fittings, other polymeric products, several types of technical gasses, sandwich panels, aluminium composite sheets, ventilation pipes and fittings, trailers and semi-trailers for trucks, specially designated metal constructions, electrical equipment, solar collectors and other products are manufactured at the enterprise. All production areas are equipped with accredited laboratories and all products are verified with the certificates of compliance. In addition, international management standards ISO 9001 and OHSAS 18001 are applied at the enterprise.

Sumgait Technologies Park participates on a number of large projects in the country, including the construction and installation of electric power stations and social facilities. It carried out the manufacturing and installation of the metal

constructions for National Flagg Square, Baku Olympic Stadium, Ismayilli Bicycle Manufacturing Plant, and many other developments. The company also has further plans to support a number of upcoming national projects, which will place it as a leading supplier of its high-quality industrial products.

The company has a large number of plants within Sumgait Technologies Park, the extensive list includes: cable plant, polymeric products plant, heavy machinery building plant, electrical equipment plant, fine mechanics plant, pressing plant, technical gasses plant, copper and aluminium electro technical rods production, hot dip galvanizing plant, sandwich panel plant, and ventilation systems production.

Sumgait Technologies Park clearly provides for a wide variety of industries, and further information about some of these demonstrates just how advanced the company’s services are.

Its cable plant is one of the largest plant in the region, and it utilises high quality equipment from technologically advanced countries to be used in the production process in the enterprise. Only

Technologies Park has to offer - the most important thing is that, the company provides to the highest standards, with certifications, and utilising the latest technology, as well as experienced employers and skilled personnel.

Having developed itself from a recent starting date, it has managed to achieve rapid growth, and created a modern collection of facilities, that can supply and support the latest developments in this quickly developing area. No doubt, Sumgait Technologies Park will play a central role in many of the major projects in the region.

Sumgait Technologies Park Products:

Electrical equipment, cables, machine building, polymeric products, steel fabrication, hot galvanizing, overhead cranes, sandwich panels, PVC windows, technical gases, solar collectors and powder coating www.stp.az

high quality raw materials, and those supplied by the leading companies of the world are used at the plant. It also only employs highly qualified specialists with wide background experience – for this reason, and many more, it means that the cable plant can be called the enterprise of the future.

Another area of Sumgait Technologies Park is the polymeric products plant, which is also one of the largest manufacturing industrial enterprises of the region, and has been in operation since 2009. This area of the company is one of the most innovative, it utilises the latest technologies made in Germany, Austria, Italy and other European countries, as well as using some of the best-known raw material manufacturers such as Borealis, Bayer, Total, and many others. All of which enable the production of market leading plastic pipes, plastic fittings, wrapped and polymeric composite pipes, and a wide number of other polymeric based products.

Another major part of the company is the heavy machinery-building plant. Sumgait Technologies Park can boast a plant with the utmost equipment - that was installed in 2010.

This section of the business provides machine building, casting, mechanical processing, crane fabrication, technical processing, smithery, manufacturing, and installation sites.

There is a number of facets to what Sumgait

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Ronaldsway Aircraft Company Limited

Technology optimised With a history dating back more than six decades, Ronaldsway Aircraft Company Ltd offers a complete supply chain solution in the provision of components and services to the aerospace industry

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perating from its original base located on the Isle of Man, situated next to the island’s Ronaldsway Airport, Ronaldsway Aircraft Company Ltd (RAC) operates as a world-class manufacturer of high-precision machined details and aircraft sub-assemblies. The company was founded in 1955 and during more than 60 years in operation has established a firm reputation as an innovative solution provider for clients with complex manufacturing and assembly requirements. Throughout this period RAC has driven forward with its continuous development and improvement culture, which has enabled the company to achieve some notable milestones during its history. These include the development of a unique ‘cradle to grave’ facility that provides the basis of an extensive range of manufacturing solutions comprised of aerospace component assembly, testing, surface and heat treatment, machining, finishing, plating, painting, fabrication, kitting and packaging services.

Ronaldsway Aircraft Company is fully AS9100 approved and holds a number of customer approvals. The business generates a turnover of over £25 million a year and operates from a 170,000 sq. ft. facility on the Isle of Man. The company is today part of the RLC Engineering Group (RLC), which is also headquartered on the Isle of Man and has sales in excess of £120 million and over 800 employees. RLC presently has manufacturing facilities in the Isle

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of Man, Northern Ireland, Northern England and Singapore, allowing the business to supply many of the major aerospace companies in Europe and North America.

By working with clients during prototyping and early product development through to the production stage and on into full life cycle support, RAC can ensure the most effective solution and the highest levels of customer service. RAC’s extensive capabilities include; three, four and five axis machining, together with sheet metal and fabrication which allow RAC to produce a wide range of different products.

The company has always re-invested in new equipment and its latest investment, a Mazak 4 axis Mill/Turn machining centre will be installed in September. This is the first machine in a significant programme of investment for this year which will not only include further major assets but also expanding and upgrading the assembly facilities and creating a dedicated prototyping cell.

This is added to the company’s range of finishing operations, heat treatment, plating and painting, all of which are NADCAP approved, and allow it to provide a complete service to its customers. It also has its own NDT facility, which is NADCAP approved. The ability to control all of its finishing operations in-house gives a significant advantage over other suppliers who have to subcontract these operations.

RAC also produces a wide array of sub-assemblies with the majority of the

components manufactured on-site. These include electromechanical actuators, flight harness buckles, timing and firing mechanisms for fighter ejector seats along with complex engine sub-assemblies for the civil aerospace market. The services the company offers include assembly, pressure testing, load and functional testing so that the finished assembly can usually be incorporated in higher levels of assembly by its customers without any further testing Its comprehensive service portfolio coupled with its membership of the wider RLC group, has allowed RAC to work with respected Tier-1 aviation organisations including Rolls Royce, MTU, Siemens, BAE Systems, Airbus, and Martin Baker. The company’s strong position and trusted reputation has allowed both RAC and the wider RLC group to win high-value contracts, as well as developing long-standing relationships with clients.

Over the last year RAC has signed a number of new contracts across both the civil and military aerospace markets, which include supplying components for the Rafale and F35 fighter aircraft, and supplying a major European aircraft engine manufacturer. RAC is continuing to grow and is actively looking at new market sectors. It has initially focused on science and technology and is now an approved supplier to CERN in Switzerland.

RAC see the spares and repairs markets in both aerospace and defence as significant opportunities. It has significant experience of

producing legacy components and re-engineering components from castings to a ‘machine from solid’ solution where necessary.

To support this renewed sales activity RAC is about to launch its own dedicated website which will stand alongside the RLC group website and it is looking at exhibiting at a number of different exhibitions over the next few years as well as supporting the RLC group’s exhibition programme.

As part of its commitment to the Investors in People programme, it is proud to hold the Silver award, and looks to provide a clear career path for all its employees. RAC has an extensive apprentice programme and typically employs between six and eight apprentices per year. It is also a major supporter of the Isle of Man apprentice training centre and the ‘Careers in Engineering’ schools programme.

As well as training and developing its existing staff, RAC is constantly looking to recruit new talent to the business. As a result of the continuing growth of the business, it will be looking to employ new staff at all levels within the organisation in the near future and has a number of current opportunities.

Ronaldsway Aircraft Company Limited Products: World-class manufacturer of highprecision machined details and aircraft sub-assemblies Contacts: Sales: Cheri Crompton cheri.crompton@rlc-ronaldsway.com Careers: Colin Bagshaw colin.bagshaw@rlc-ronaldsway.com Ronaldsway Aircraft Company Limited Ballasalla, Isle of Man. IM9 2RY Tel +44(0) 1624 820555

www.rlc-ronaldsway.com

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James Dewhurst

Expanding

horizons

James Dewhurst designs and manufactures high performance engineered reinforcement fabrics to ensure optimum performance throughout the supply chain using a wide range of material types

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rom James Dewhurst’s origins in 1933 as an innovative weaving business, it has grown into one of the largest global manufacturers of flexible reinforcement materials. Over the last 80 years, it has built on this heritage with proprietary laid scrim processes, chemical binders, and lamination and weaving technologies. Dewhurst’s high-performance industrial woven materials allow it to offer competitive reinforcement solutions tailored to its customers’ requirements.

As part of the future planning at James Dewhurst, a new team has been put together in order to ensure that it is taking a proactive and energetic approach to targeting the geotextile and construction market. Having only recently been implemented, it will likely prove to be an important strategic move, as Group Sales Director Jean Claude Abed discusses: “This geo textile market team has been assembled with the sole focus of identifying opportunities whereby James Dewhurst products may be applicable to the geo textiles and construction industries particularly. The group will also focus on developing new products for customers through partnerships and close relationships with customers.”

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Geotex Scrim selection

Monosuisse

Monosuisse, as one of the world’s leading producers of monofilaments has been a reliable partner for James Dewhurst Ltd for more than one decade.

Its common philosophy about high quality, engineered products and ongoing developments, is the key for the success of both companies in the market.

Monosuisse has four production facilities worldwide and offers an extensive range of monofilaments with special polymers for various applications. High tenacity multifilaments for technical applications are a new addition to its range of products.

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The new group has already seen some dividends for its efforts, and Jean Claude provides an example: “We have had some successes already in the US where we supply polyester reinforcement scrims to reservoir liners. We sell the scrim to essential polyethylene film extruders that laminate our scrims to their extrusions to provide a reinforcement and then these are laid in the bottom of various ponds and reservoirs as a barrier layer and then the water gets added on top of it.”

He adds: “In addition to reservoir liners, another successful application has been developed in partnership with one of our customers; this is a glass reinforced laminate that is used in road construction applications in the US and was produced to meet the needs of the road construction business in North America.

We have also developed a third product that is also for roofing; it is a glass scrim laminate that differentiates itself from other types of glass scrim as it is based on a roving yarn instead of a multi-filament yarn. This makes the glass scrim laminate a very high strength glass yarn and is part of our efforts to deliver a glass woven, glass tissue laminate for the roofing industry in Europe.”

The market is always a significant factor in any company’s success, and will affect its customers demands, and Jean Claude has a positive outlook for the situation in Europe, particularly for James Dewhurst: “I think overall Europe is seeing slow to moderate growth in general – so there is new business for us, but it is not necessarily only new business that our growing demand is coming from. A substantial part of it is coming from us taking more of a share of one customer or another. We do believe that things are starting to look better, and we have been getting many more developments and opportunities, as well as requests and partnerships with customers, over the last six months. We expect this to be the case in the coming 12-18 months, as we feel that not only are we looking to further develop our business but our customers are also looking to grow theirs.”

Jean Claude also discussed the areas that are seeing the greatest improvement: “The most strategic growth for us is in the geo textile and construction markets. As I mentioned we put together this focus team to drive that. They are really starting from scratch – so for us this is a completely new business and that takes time.

We have to develop a lot of opportunities and

James Dewhurst

Geotextile team

a lot of the products, we will go out and identify the customer and find their unmet needs, to then work with co-operatively to develop some new products.

“For example, in construction we are looking to target roofing applications; previously we have made a lot of roofing laminates made from glass scrim, laminated to glass tissue, but have recently developed a laid scrim to replace the woven scrim that is historically used to create a single ply roofing application for TPO or PVC roofs. This development is in response to market trends whereby woven reinforcement is being substituted with a laid reinforcement; this is

a new business for us and has recently been commercialised with one of our customers.”

There are always new areas in which James Dewhurst is looking to improve, so the company has a very active future planned, as Jean Claude discussed: “We are also evaluating and running trials for the next four weeks whereby we hope to be able to offer a new bio compostable scrim.

This is an area where a lot of customers have expressed interest but a lot of the materials that would work in our process were not available until this time or were very expensive to the point where it didn’t make any sense. So we hope in the next six months to have two or

three different bio compostable options available as reinforcement to customers targeting hygiene areas like wipes. This will allow packaging customers to prevent a lot of paper going to landfill, and instead make it compostable. Those are probably the biggest areas of growth that we expect to get into.”

The company is putting in place innovative plans for the future, new energetic teams, investments in its facilities, and increasing its market share within Europe. James Dewhurst developed an impressive business in the 20th century, and the company no doubt has an even more successful future ahead as it continues its focus on innovation and a collaborative approach to product development.

James Dewhurst Products: Flooring and roofing products, needle punching and filtration fabrics and wind turbine blade reinforcement

www.jamesdewhurst.com

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Widex

Widex CO2 neutral HQ

Hear

here

By developing digital technology at a level of quality few can match, family owned company Widex has earned a strong reputation as one of the most innovative manufacturers of hearing aids in the industry

Widex new automation system

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ounded in Denmark in 1956 by Christian Topholm and Erik Westermann, Widex has remained true to its roots by focusing on the technical development and manufacturing of high-quality hearing aids, as well as the sales and marketing of products. Renowned for the unique sound of its products and state-of-the-art technology, Widex provides a full line of hearing solutions for all types of hearing loss.

The company has a history of developing many of its own manufacturing equipment and production processes. Julian Topholm, Vice President of Production Technology at Widex and grandson of founder Christian Topholm, explains: “Traditionally we have done a lot of work in-house. Processes like nano coating, electronics mounting, rubber moulding and coil-winding are examples of this.

We have a history of process development that leads us to constantly push our production process to the limit of what is possible. We have just finished installing our largest machine ever, a 600 m² automated testing machine that can assemble, test, calibrate, program and pack hearing aids. Looking at the way the market is evolving, I would say automation and process development is something that will continue to be focus points for us in the future.

“Our legacy of development and innovation has cemented our focus on quality and this commitment has kept us in business in a competitive market since 1956.

An important part of our success is our technical expertise and solid reputation for producing some of the best hearing aids in the market; in the last 20 years we have pioneered developments like remote controlled hearing aids, digital hearing aids, as well as the use of 3D printing for moulds and shells,” he adds.

Today, Widex employs almost 4000 people worldwide, out of which 850 work at the company headquarters in Lynge, Denmark. The owners are closely involved in the company, and Widex enjoys an open-door culture and a high level of employee engagement. Alongside its headquarters, the company also boasts a large network of sales companies as well as manufacturing facilities in Estonia,

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Unique hearing aid family

where the labour-intensive assembly of parts takes place.

As an independent, family-owned company, Widex has the freedom to make long-term investments that bring the company closer to its vision without having to take into consideration obligations to shareholders. This way of operating has proven fruitful for the innovative company - as shown by the latest positive financial statements released in August 2016.

quality. Modern hearing aids are complex – part of the challenge is to establish the scope of sound and decide which sound sources need to be amplified and which need to be suppressed, as well as how to reduce feedback (whistling) and how to apply noise reduction. There are a lot of opportunities to continue developing even better products both when it comes to sound quality and other features like connectivity.”

Widex has a proud tradition of innovation and was the first company to bring a fully digital hearing aid to the market – a technology that revolutionised the industry; today all hearing aid manufacturers only produce digital hearing aids.

Having established a solid foothold in the hearing aid industry as one of the most important

global players, Widex is well positioned to continue its innovative legacy.

Julian expects automated production technology to be an integral part of this: “We see strong growth over the coming years, and a bottom line that follows it, as our products become easier to manufacture while we work to increase the level of automation.”

Widex Products:

Hearing aid solutions www.widex.co.uk

UFM hearing aid

Discussing the importance of innovation, Julian comments: “Technology is key and the process of R&D is very important to us. Over recent years, a lot of our R&D has been focused on connectivity, that is the ability to connect hearing aids to other devices such as phones, tablets, computers and so on. This is something we will continue to work on while maintaining our strong focus on sound

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Enesco

The gift of

giving Enesco LLC, a leading giftware company, has been designing and selling top quality products since 1898

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erving over 40,000 customers across the globe, Enesco distributes merchandise to a large assortment of card and gift retailers, and home furnishing stores, as well as well known leading chains and retailers trading on the internet. With its international headquarters located in Itasca, Illinois, Enesco has subsidiaries in the United Kingdom, France, Canada and Hong Kong, serving markets operating in Europe, the Americas, Canada, Australia and Asia.

The huge range of product lines available from Enesco include some of the most well-known brands from across the globe, and Enesco is renowned worldwide for stocking the most innovative and entertaining items, stylish decorations for interiors, inventive products for the garden, and sought-after collectibles. Its exceptional assortment of high quality products includes licences for all-time favourites.

The huge range of products available include calendars, Christmas decorations, drinking glasses, egg cups, key rings, magnets, photo frames, stationery and wall art. One of the brands featured in the Enesco portfolio is Gund — a very prestigious soft toy company from the United States that has a heritage stretching back over a century. Renowned for being behind the creation of some of the world’s most adorable soft toys, Gund’s ranges include classic teddy bears, soft and activity toys for young children and licensed ranges based on various characters including social media stars - the world’s cutest dog Boo, the infamous Grumpy Cat and cartoon and Facebook favourite, the adorable cat character Pusheen.

Another favourite brand is Designs by Lolita, the brainchild of a designer who was inspired to create decorated glassware after a night out with the girls. Designed to help consumers all over the world celebrate life’s occasions, Providence, Rhode Island-based Designs by Lolita has sold over 14 million glasses since its inception in 2004.

The hand painted glassware collection features an informal style of illustration, on a hand blown glass. Available for a variety of gift occasions, these glasses are bound to delight any recipient – for example, teachers are

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sure to love a special wine glass for the end of term! The glasses are very distinctive and celebrate occasions with a glamorous twist.

Designs by Lolita was added the Enesco brand portfolio in May 2015, when it signed a license agreement to be the worldwide manufacturer and wholesale distributor for the glassware.

Kathi Lentzsch, president of Enesco Gift said at the time: “Lolita has been an admired brand for many years and is enormously popular with consumers and retailers alike. The engaging, fun, artistic designs and giftable products make Designs by Lolita a perfect complement to the Enesco family of brands. We look forward to working with Lolita and her team and are delighted to offer these great products to Enesco’s customers.”

“I am thrilled to partner with Enesco,” added Lolita Healy, CEO and founder of Designs by Lolita. “When I started out, just a gal with some hand-painted martini glasses, I never imagined how much the brand would grow. I am excited about the potential that lies ahead and confident Enesco can help us take Lolita to new heights

while delivering fabulous products to our fans.”

For those looking to see Designs by Lolita or any of the rest of the products Enesco makes available, its website is a hugely helpful resource.

It not only illustrates the range of products to be had, it also offers assistance to visitors, by suggesting the right present, giving the option to chose by recipient and/or occasion. Special events listed include anniversaries, weddings, christening and even bereavements, but of course special birthdays are high on the list and items such as figurines and soft toys are suggested as the ideal gift for men, women and children.

The website also lists retailers that stock the products, and these are especially selected suppliers located throughout the UK and the rest of the world, that have worked with Enesco and established relationships based on superior quality and service. And of course, Enesco’s own customer service department is on hand to assist if there is any issue with tracking down the perfect item.

For anyone looking for that perfect gift, Enesco is the surely the first place to start.

Enesco Services:

Giftware company www.enesco.co.uk

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