Fletcher Moorland News

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Fletcher Moorland

Issue 1

Night owls keep repairs flying out around the clock PAGES 10&11

ELECTRONIC DIAGNOSTICS WITH PINPOINT ACCURACY PAGE 7

TRAINING ENGINEERS FOR THE FUTURE PAGE 15

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An emergency service ready to respond 24/7

By Matt Fletcher MANAGING DIRECTOR

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T Fletcher Moorland we think of ourselves as an “accident and emergency” service for industrial electric motors, pumps, gearboxes, printed circuit boards, inverter drives and servo motors. Just like a hospital casualty unit, we are ready to respond 24 hours a day – 365 days a year.

Whatever the time – day or night – our customers know they can turn to us to get their equipment fixed as quickly as possible.

Our vast range of engineering skills and disciplines gives us confidence that we can sort out almost any machine breakdown – from the first control system to the last mechanical movement. Our first task is to find out what has gone wrong and then to tell the customer how long it will take to repair so they can plan around any downtime.

We put great store by keeping our customers informed – it is an important part of our service because it is vital to factory maintenance managers.

Sometimes a repair can be done in hours and more extensive work can take days – but we always aim to keep our turnaround time to a minimum.

However, speed is only part of the equation.

We make sure the repair is done to the highest standards – so the equipment is as good, if not better, than when it was new. This is achieved by a mixture of engineering best practice, using top quality parts and providing industry-leading guarantees.

To continue the health analogy, we like to take an holistic approach to factory equipment maintenance.

It is not just a case of responding to a breakdown – we look at the bigger picture to make engineering adjustments and take preventative measures which will reduce the number of breakdowns. That cuts downtime and saves our customers money.

We even have a fleet of vehicles ready to go out to factories to collect and bring back the problem parts to our workshops in the heart of the UK at Stoke-on-Trent. This fleet is backed up by a network of couriers throughout the country and Europe to ensure that, when urgency is of the essence, transporting the equipment is not an obstacle.

On a personal note, I am proud to say I have worked at every level at Fletcher Moorland. (I started at the aged of nine when my father gave me a Saturday job sweeping the factory floor!) So I know at first hand the professionalism and expertise we have throughout the company. They are very healthy attributes – and ones which enable us to take good care of our customers.

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Managing Director Matt Fletcher

Fletcher Moorland 24 hours a day hotline – 01782 411021

Passionate about running an EFFICIENT OPERATION

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IANE Mansell entered the male-dominated world of engineering after 17 years in the food manufacturing industry and soon found that the change in career was to her taste.

The Operations Director is responsible for the day-to-day running of just about every aspect of Fletcher Moorland’s operation, making sure it runs smoothly, efficiently and meets the needs of customers.

During the six years in her present role, Diane has seen the specialist company expand dramatically, winning new overseas business in Europe which now accounts for 20 per cent of Fletcher Moorland’s client base.

Diane was Production Manager for a reputable ice cream company in Telford then HR Manager for another food production firm in Skelmersdale. Personal reasons brought her back to her home city of Stoke-on-Trent 13 years ago.

She joined Fletcher Moorland as Logistics Controller, then for a spell was PA to the then Managing Director before becoming General Manager. She was promoted to her present senior management role six years ago.

Diane’s wide remit involves sales and sales forecasting, customer account management, production planning, human resources, logistics and financial accounting. In fact on a day-to-day basis she closely monitors each job, working with the departmental managers from initial inquiry to completion.

She also has ultimate responsibility for seeing that Fletcher Moorland’s fleet of six vehicles up to 7.5 tonnes and the company’s network of couriers throughout the UK meet the aim of collecting faulty equipment from a customer within 24 hours of their initial call.

It’s this attention to detail and customer service, together with effective networking and marketing that has helped Fletcher Moorland develop its business across the Channel in France, Germany, Italy, Spain, Belgium and Luxembourg.

Diane said:“I joined Fletcher Moorland with a background in production and human resource and I feel that I have been given a great opportunity to use my past experience to benefit the company. I’m passionate about all aspects of our operation but in particular I get a huge sense of personal achievement when involved in sales and HR.”

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Operations DIrector Diane Mansell at her desk at Fletcher Moorland.

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I joined Fletcher Moorland with a background in production and human resource and I feel that I have been given a great opportunity to use my past experience to benefit the company.

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“”

I have to have a crystal ball and identify what might go wrong for the customer. I look at areas such as motors, gearboxes, fans, pumps and electronics to help customers avoid problems happening in the first place.

N O T N U O C N A C S R E M O T S CU

Reliability Engineer Dave Daly takes a close look at a motor in for repair.

Y T I L I B A I L E R R M

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Hard work and innovation has earned company a

NATIONAL REPUTATION I

N a specialist industry that sees many companies come and go, Fletcher Moorland Limited has stood the test of time. It is more than 66 years since Sam Fletcher – grandfather of current Managing Director Matt Fletcher – formed Electrical Rewinds & Supplies to begin a business that over the decades was to develop into one of the UK’s leading players in electro-mechanical and electronics repair and maintenance.

Hard work and innovation helped to earn the company a national and international reputation for quality and reliability – attributes that today are still very much part of the Fletcher Moorland DNA.“We won our spurs the hard way,” said Malcolm Fletcher, former Chairman and Managing Director, who is still a working director.

“Having a ‘can do’ attitude is central to our business philosophy. We look after our customers and make sure we respond when they need us. That is why we provide a round-the-clock service 365 days a year which is a big and expensive commitment of resource – but one which we believe is worthwhile and is appreciated by our customers.

“Always being available is only part of the story. We have also consistently delivered a top quality and reliable service which has required

engineering innovation. This has given us a competitive edge and provides our customers with the added value they are looking for.”

Malcolm points to the continual investment over the years in the latest equipment and technology and also, in what is perhaps the company’s most valuable asset – its highly skilled workforce.

“Our specialist expertise in electromechanical and electronic engineering has been developed over decades but particularly over the past five years,” he said.

“We have focused on repair and remanufacture and in this field we have engineers who are among the best in the world.”

As the company continues to expand and develop new markets for its services, Malcolm looks to a bright future for Fletcher Moorland – based on the same sound business culture that has stood it in good stead for so many years.

He added:“We never rest on our laurels – we have to keep adapting, investing and improving to stay at the forefront of our industry. That innovation is vital as we go forward.”

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We look after our customers and make sure we respond when they need us.

DIrector and former Chairman Malcolm Fletcher.

Inset left, the company founder Sam Fletcher.

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The Formula 1 I

of electric motors

Servo Motors Manager Alan Palmer, right, and Engineer Adrian Chuter repairing a servo motor.

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F you compare a standard electric motor to a typical family saloon, then a servo motor has to be on a par with a cutting edge Formula 1 racing car.

They are highly sophisticated pieces of equipment that power complex machines – such as automated robots or computer numerically controlled (CNC) machines… and it’s in this area of engineering where Fletcher Moorland’s specialist expertise really excels.

For more than 20 years the company has run a dedicated servo motor workshop and the six-strong team now repairs more than 1,000 units a year from the UK, Europe and USA. The burgeoning division works with high calibre customers such as Toyota, Nissan and Rolls Royce, and is recognised as confidential repairer to a number of major original equipment manufacturers.

Alan Palmer, who manages the workshop, delivers specialist on-the-job training to his team members who learn their skills as their careers progress.

He said:“We repair and maintain the full range of servo motors. The work can vary from simple jobs such as changing the bearings to the complex set up procedures of modern programmable encoders.

“Training is on the job because it is so specialised that college courses can’t teach it.

It means our team have a wealth of skills that companies need to turn to and rely on.”

A huge factor in Fletcher Moorland’s success has been continual investment in the servo motor department.

In 2007, £250,000 was pumped into new equipment, workshops and development at the company, which included a complete refurbishment of the servo motor workshop and new servo test equipment development.

Alan added:“New servo motors are being developed all the time and are getting more sophisticated. This is why we have to keep up by having the latest equipment and software to repair them.

“For instance, we have invested considerably in a new encoder programming kit but we will continually have to upgrade it so we stay at the cutting edge of the industry.”

Fletcher Moorland 24 hours a day hotline – 01782 411021

PINP INT

Electronics g in t o o h s e l b u o tr with

PINP INT ACCURACY

Technical Director Geoff Rigby, below, works on a circuit board using the Pinpoint IIR diagnostic machine.

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HE Drives and Controls department at Fletcher Moorland works round the clock to ensure that disruption is kept to a minimum for customers when a vital piece of equipment needs to be repaired.

A team of engineers operate three shifts over 24 hours to work on printed circuit boards (PCBs) and complete drive units to locate faults and rectify them as part of a fast and reliable service.

The last 12 months has seen a record investment by the company in electronic drives and controls equipment – including the cutting edge Pinpoint technology, a £50,000 electronics diagnostic machine that brings together a number of testing procedures in a single piece of equipment.

This gives the ability to diagnose faults on the most complex, modern PCBs. Along with 25 years of experience in the repair and testing of PCBs, Fletcher Moorland has established its own in-house Research and Development centre that constantly reviews testing methods and equipment.

Drives and controls engineers are trained to the highest industry standard of IPC 7711/21 in the rework and repair of electronic assemblies.

Technical Director Geoff Rigby, who has 20 years’ experience with Fletcher Moorland, said: “Our drives and controls team closely follow advances in the electronics industry in order to ensure our service is second to none.

“This industry does not stand still and we have to keep up with each new development.”

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Our Drives and Controls team closely follow advances in the electronics industry in order to ensure our service is second to none.

GEOFF RIGBY

TECHNICAL DIRECTOR

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Delivering

GOOD NEWS

by helping to keep PRESSES ROLLING

“” FLETCHER Moorland Ltd was able to deliver some good news to the company that prints North Staffordshire’s daily paper The Sentinel.

The two presses at the Etruria, Stoke-on-Trent publishing centre will continue to roll for many years to come, thanks to a carefully planned programme of refurbishment for the large specialist servo motors that are a vital component of the printing process.

One of the presses is powered by 17 Indramat motors while 34 more are used on the other press and until two years ago the motors were serviced by the manufacturer.

However The Sentinel were told by the manufacturer that the motors had exceeded their normal operational life – substantially increasing the cost of repairs and servicing.

That’s when Technical Manager Jeff Hilditch contacted Fletcher Moorland’s Managing Director Matt Fletcher and found a very local solution to their problem.

Fletcher Moorland drew up a plan to completely re-build all the motors at a fraction of what it would have cost to purchase new ones. The components are being refurbished one at a time and it takes around two weeks to restore each one to mint condition.

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Fletcher Moorland came up with a rebuilding programme that is extremely cost effective and meets our needs perfectly JEFF HILDITCH

TECHNICAL MANAGER

Meanwhile The Sentinel keep a number of Indramat motors on stand-by in case of a breakdown to ensure the presses – which print up to 60,000 copies of The Sentinel a day five days a week and 300,000 copies of The Daily Mail and Mail on Sunday seven nights a week – are not interrupted by servo motor failure.

Jeff said: “We have embarked on a long term project of motor refurbishment which will take about five years. Fletcher Moorland came up with a rebuilding programme that is extremely cost effective and meets our needs perfectly.”

Fletcher Moorland 24 hours a day hotline – 01782 411021

Repairing robot motors THROUGHOUT EUROPE F

ANUC Robotics is a world leader in the production of industrial robots and robotic automated systems – and a number of their European customers entrust Fletcher Moorland with the repair and servicing of the servo motors that drive their robotic assembly and production lines.

With 240,000 of their robot systems installed worldwide, Japanese-owned FANUC supplies tailor-designed products for the aerospace, consumer goods, metal fabrication, medical, pharmaceutical, solar panel and many other industries.

Their robots have payload capabilities ranging from 0.5kg to 1,350kg, and the company also designs and manufactures simulation packages, application software, force sensing and iRVision. FANUC produce their own servo motors at their in-house factory in Japan.

Among the customers of Luxembourg based FANUC Robotics Europe, who regularly send their servo

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motors to Fletcher Moorland from plants all over Europe, are blue chip names such as Coca Cola, Hoover, Opel and Suzuki.

All of them are industries where continued production is a priority and who therefore require a highly dependable repair and maintenance service to prevent any disruption to the flow of the assembly process.

Andy Smith, FANUC’s General Manager for European Customer Services, said: “Feedback we have received from some of our major customers about the repairs undertaken by Fletcher Moorland confirm the work they carry out has consistently been of a high standard and very satisfactory for the customers involved.”

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NIGHT OWL KEN AND S HIS TEAM ENSURE REPAIRS FLY OUT

AROUND THE CLOCK

ELF-CONFESSED night owl Ken McCleaft is happy with his twilight role at Fletcher Moorland where he is Night Shift Site Manager.

The post has been specifically designed to meet the growing demand from industrial customers for an overnight repair service in order to keep their production rolling.

As a keen stargazer US-born Ken is used to being wide awake when most people are asleep – and back home in the States he often worked late as a back stage and front of house volunteer for a community theatre.

Now Ken leads the seven-strong Fletcher Moorland team that works through the night and usually comprises four engineers dealing with electric motors, two on drives and controls and one on logistics.

Ken was born in Long Island, New York, but his work as a computer engineer, some of it for the US military, took him to Los Angeles, Memphis, Minneapolis, Virginia and Maryland. Again, it was a job that often kept nocturnal Ken working late into the night.

Through a mutual friend Ken came into contact with Fletcher Moorland’s Technical Director Geoff Rigby, who shares the American’s passion for astronomy and amateur radio, and in 2003 Ken “crossed the pond” to join the company in the Research and Development department.

He said: “A lot of the work we do at night are repairs that customers have tried

Night Shift Site Manager Ken McCleaft ready for another busy evening.

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Fletcher Moorland 24 hours a day hotline – 01782 411021

unsuccessfully to carry out themselves that day.

“We have the repaired unit back to them the following day so production is not affected.

“Also in this period of downturn, customers are opting to repair faulty equipment rather than replace it and this also keeps the night team busy.”

Ken added:“I love living and working in this country and I haven’t been back to the US since arriving here nearly 10 years ago.”

Night Shift Logistics Co-ordinator Phil Sutch monitors the company’s vehicle tracking system in order to direct the nearest vehicle to a customer call out.

Ken with part of the night shift team

Meet Matt Sparks... he’s a real livewire!

MATT Sparks has the perfect name for a career in electrical engineering and his current role is Electro-Mechanical Workshop Manager. The 38-year-old, pictured left, took charge of the department in January this year after joining the company 13 years ago. Promotion followed as he vowed not to remain static.

He now manages around 20 fitters, machinists and winders working three different shifts to keep the workshop operating 24 hours a day, seven days a week.

His highly skilled and experienced team use state-ofthe-art equipment as continued investment gives them the machinery and equipment to keep them at the forefront of the repair industry.

He said:“I get a real buzz out of working in an ever changing industry. You never know what’s going to come in from one day to the next.

“It can be very stressful but it’s massively rewarding when we hit targets. Our engineers are vastly experienced, flexible, hard working and always deliver.

“After 10 years on the shop floor, I’ve built a close bond with the guys. I think we’re second to none as we push the boat out – a real close team.”

Away from work, Matt enjoys football and golf and spending quality time with his sons aged 10 and 13.

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Steve Robson, right, and his brother Phil in the Electro-Mechanical Workshop.

Engineering is in BROTHERS’ BLOOD B

ROTHERS Steve and Phil Robson have always played for the same sports teams – and are still on the same side as they work together at Fletcher Moorland.

Now in their 50s, they often find themselves on neighbouring benches in the Electro-Mechanical Workshop where they both fulfil the roles of fitters and site engineers.

Steve, 50, first joined up from school in 1978 while Phil, aged 54,

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arrived in 2007 after a career elsewhere as a maintenance engineer. Engineering is in their blood.

“We loved Meccano when we were kids and making model aeroplanes.

We used to play for the same football teams and we’ve played badminton and golf together all our lives,” said Steve, who is married with two children.

“I can’t remember us ever falling

out. We’re both quiet and down to earth so we get on really well at work.”

Phil said: “I just wanted a change of scene and Steve fixed me up here.

It’s a little different from what I was doing before so I asked him a lot of questions in the early days. He’s always dead helpful.

“I soon picked things up as the whole team helped so everything is fine now. I’ve really settled in.”

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HEN it comes to winning new contracts and keeping existing customers happy, former ice cream factory worker Andy Mansell has got it licked.

Customer Service and Sales Manager Andy, pictured right, leads a five-strong team who have a track record for identifying potential new business and going the “extra mile” for current clients.

Andy said: “When it comes to selling the company, Fletcher Moorland’s reputation speaks for itself. We have a very good name with our customers for going the extra mile and receive a lot of referrals for work as a result of this.

“The team has an extensive current and potential customer database and uses this to generate new leads.

“We tend to target large companies in areas such as the automotive industry or food and drink manufacturers and then meet face to face.

“The best way to sell our services is in person – it gives them a feel for who they are doing business with and they can also gauge that you are trustworthy and credible.”

Fletcher Moorland’s customers can be found throughout the UK and Europe – and even in the United States and Japan. Their enviable reputation is based on a combination of an honest approach and a reputation for quality.

Andy added:“We’re always direct and honest and lay our cards on the table from the off – it’s an approach companies appreciate.

“They also know they can rely on our repair skills and the high quality workmanship and parts we use. We are always proactive. So if we are on site at a company we are constantly testing their motors to ensure they are running correctly. It saves the company a large repair bill and unneeded downtime later.”

On a personal note, Andy has to be on his mettle in the workplace… because his wife Diane is also Fletcher Moorland’s Operations Director.

The couple met 22 years ago when they were both working at an ice cream factory in Telford – and it’s fair to say their hearts melted.

“She was the production manager and I was a machine operator and, well, we simply fell in love,” he recalled.

“Several years later Diane came back to her native Stoke-on-Trent to be Fletcher Moorland’s Logistic Controller and I came with her and joined as a general duties operative.”

He added:“We have our moments like any couple – but at work it is purely professional and we have a great working relationship.”

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“”

The best way to sell our services is in person – it gives them a feel for who they are doing business with and they can also gauge that you are trustworthy and credible.

ANDY MANSELL

CUSTOMER SERVICE & SALES MANAGER

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Royal Navy man sails into

a new career W

HEN Richard Urwin disembarked from his career with the Royal Navy he sailed straight into a new job with Fletcher Moorland.

The former weapons engineer who served on board HMS Gloucester swapped tours of duty on the seven seas for a new life with the Servo Motor Division.

He has signed up as a trainee engineer and is learning to repair some of the most sophisticated servo motors being used in a wide range of industries.

Richard, 22, spent three years with the Royal Navy.

However, after a seven-month tour on board the Type 42 Destroyer in the South Atlantic – including patrols around the Falkland Islands – he decided to drop anchor back in the UK. He said: “My girlfriend was back at home in Stoke-on-Trent, and the more time I spent away the more I missed her.

“I was interested in an engineering career in civilian life and my uncle, Dave Urwin, who used to work here, was quick with a recommendation.

“He said that if I was looking to learn my trade thoroughly there was no better place than Fletcher Moorland.

“Training is on the job under very experienced supervision and it is a steep learning curve. It is constantly challenging me and I am able to work with some of the most complicated precision motors.”

He added: “Both my uncle and my cousin worked here for many years and I can definitely see me following suit. I am really glad I made the change of career.”

“”

My uncle said that if I was looking to learn my trade thoroughly there was no better place than Fletcher Moorland.

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Richard Urwin with a batch of Fanuc servo motors.

Fletcher Moorland 24 hours a day hotline – 01782 411021

Engineering Manager Dave Elks passing on advice to Winder Mike Dukes about a repair to a three phase motor.

Below, Mike brazes a connection.

TRAINING ENGINEERS

FOR THE FUTURE W

INDER Mike Dukes has just completed his apprenticeship as Fletcher Moorland continues to invest in upskilling its staff to provide the engineers it needs for the future.

The 24-year-old already had a National Diploma in Electronic Engineering from Newcastle College in his back pocket when he was taken on as a trainee apprentice winder in 2008.

Block release courses at Loughborough College filled in the gaps in his knowledge while college assessors continually checked that his practical workplace skills were up to scratch.

Mike said:“It’s what I’ve always wanted to do so I’m chuffed.

I get a lot of satisfaction from my job and at some point would like to move on to a supervisor’s role.”

His mentor over the five-year apprenticeship was Dave Elks, 62,

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the former Electro-Mechanical Workshop Manager who is now Engineering Manager.

He said:“He’s come through well. He’s passed his exams when some on the course dropped out or failed so that’s pleasing for us.

“There is a lack of young engineers at the moment so we need to train people up. I’d encourage young people to come to us.

“We have a terrific amount of experience and the work is varied as we service a vast array of companies. I’d say we’re second to none.”

Operations Director Diane Mansell said: “It can be a struggle to get young people interested in engineering so we offer flexible and practical training. We also provide a best practice workshop service to our customers who often send us their apprentices to experience our workshops.”

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We have a terrific amount of experience and the work is varied as we service a vast array of companies.

DAVE ELKS

ENGINEERING MANAGER

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Drives Engineer Julian Coupe testing a Siemens servo drive.

Servo Engineer Steve Robinson testing a Fanuc servo motor.

Fitter Kevin Bradshaw measuring a bearing housing using the co-ordinate measuring machine.

Fitter and Site Engineer Phil Robson testing the stator windings of an electric motor.

Machinist Craig Dudley balancing a rotor.

Night Shift Site Manager Ken McCleaft repairing a faulty Fanuc servo drive.

Fletcher Moorland Ltd, Elenora Street, Stoke on Trent, ST4 1QG, UK I Phone: 01782 411021 I Fax: 01782 744470 I Web: www.fletchermoorland.co.uk