Fletcher Moorland News

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K E E P I N G

I N D U S T R Y

R U N N I N G

Fletcher Moorland

news Automation spares division is fast expanding PAGE 3

ON SITE SERVICES CUSTOMERS CAN RELY ON PAGE 4

PCB DESIGN & MANUFACTURE IS A BIG MONEY SAVER PAGE 5

WIN A SINGLE MALT WHISKY IN PICTURE QUIZ PAGE 14

www.fletchermoorland.co.uk

Issue 2

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Pledge is to always provide a solution ELCOME to our 2015 magazine, which will keep you informed about the very latest initiatives at Fletcher Moorland and our exciting expansion plans.

The last 12 months has been a very good trading period for us and we have experienced growth in all divisions of the company. Strong markets have been the automotive, food and drink and hi-tech manufacturing sectors where we have won several new contracts for asset management services.

This had led to an increase in staff at the company and has seen us recruit a number of apprentices – recognition that we need new and young people to help drive forward the business.

Our pledge to customers is that we always offer a solution – and we never leave them with a problem. From my experience, no company can repair everything and I would be wary about those who claim to be able to do so. Our approach, to coin our own phrase, is to use the four R’s of maintenance engineering – Repair, Refurbish, Replace and Retrofit.

Through this method we are able to guarantee a solution that will satisfy our customers’ requirements. We have also broken new ground by establishing several new

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By Matt Fletcher MANAGING DIRECTOR divisions that you will be able to read about in this magazine. Major investments have been made in equipment and infrastructure in our workshops and we always encourage customers to come and see our operation for themselves. It is said we have one of the best workshops of its kind in the world.

We have signed up to Google Business View which allows people to take a 360-degree virtual tour of our workshops.

Talking about our workshops, as our divisions continue to grow we are now looking at how to accommodate that expansion. We have been on this site since 1953 and must soon decide whether to increase the size of our presence here or look to a totally new site.

As we approach our 70th anniversary, we very much look forward to continuing to offer our renowned 24/7 service to our customers, building on these relationships and forging new ones.

Finally, I would also like to take this opportunity to pay tribute to a much-missed

member of staff who passed away last summer.

Pete Heath was based in our mechanical department and continued to work as long as he could throughout his illness. In his memory, we will be raising money for the Douglas Macmillan hospice where he received care.

Exciting developments to boost our service IT’S unbelievable how quickly time goes by when you enjoy your job. I’m now in my 18th year with Fletcher Moorland and I can honestly say no two days have been the same.

My role is to ensure that the company achieves profitable growth within the market place and since our last magazine I’ve been elected a Member of the Association of Accounting Technicians.

This qualification, combined with my background in production and HR, has allowed me to focus my attention on sales, production, HR and finance.

In the last few years, Fletcher Moorland has seen a sales growth of 25 per cent. This has resulted in a recruitment drive in all areas of the business from customer service, machine fitters and site engineers.

As part of this, there are some exciting developments that have already taken place or to look forward to.

Automation Spares was launched in January this year and the business is already thriving. This year will also see

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Fletcher Moorland news

By Diane Mansell OPERATIONS DIRECTOR

the launch of our bespoke in-house computer operating system, designed and built by our IT department with customers in mind.

We know our customers’ time is precious and business performance ever more demanding and with this in mind we are always looking at ways to improve our interaction and keep up to date with their needs.

Each customer has the facility, via our website, to access all their data through a dedicated and secure online database.

New features this year will be live web chats regarding plant reliability and repair trending. It means customers will be able to communicate via the web link and their requests will automatically be directed to not only their Account Manager but also the engineer that is assigned to them.

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FML’s Automation division has an extensive range of spares in stock.

Automation spares division is winning global business USTOMERS around the world are contacting Fletcher Moorland to buy obsolete and hard-to-find automation parts to keep the wheels of their businesses turning.

A brand new division called FML Automation Spares has been set up to source, stock and supply the parts, which can range from servo drives and programmable logic controllers to HMIs and servo motors.

The company has already sourced thousands of parts, which have been quality tested and, where necessary, refurbished – these are then stored on site at Fletcher Moorland.

So far customers from as far afield as Mexico, Peru and the USA have bought items, alongside many others in Europe and around the UK. Matt Fletcher said: “It is a way to help manufacturing plants manage their equipment obsolescence. Typically Original Equipment Manufacturers make parts obsolete after six to 10 years and then withdraw support. When a replacement part is needed, getting hold of one is much more difficult.

“We are not only able to repair automation parts but through this division supply from our growing stock – saving customers thousands of pounds in new machinery.

“Where our approach differs is

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in the engineering knowledge we have – we are not just traders of parts. I know of several companies in this business who, for example, just box and ship parts from overseas with little consideration for their condition.

“Imagine that you have a car that was built 20 years ago and has never been driven, would you drive it down the motorway without checking and servicing it first?

“No of course not, but that’s what companies are doing and then relying on them to operate reliably in their production machinery. We will fully service and refurbish any part we sell and cover it by a 12 month in service warranty.

“Anyone around the world can access the type of parts we stock through our website – they can then pay online and we can ship out the item to them wherever they are.

“We will buy stock from OEMs, traders and customers who are getting rid of it because they see it as obsolete. These include companies like Fanuc, Siemens, Allen Bradley and Bosch.

“Our aim is to build up the items we have in stock and expect demand for the service to really grow over the next few years. We are targetting Eastern European countries and emerging markets because we believe there will be a big demand for the service there as well as our domestic market.”

Dan Mansell selects a Fanuc series unit from the spares store for shipment to a customer.

Fletcher Moorland news

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RELIABILITY MOTTO: If it’s not broken,

IMPROVE IT ELIABILITY Engineer Tom Hughes has a very simple motto when working for Fletcher Moorland clients that perfectly sums up the company approach – if it’s not broken, improve it.

The 57-year-old joined the company in September last year to strengthen Reliability Services and now works alongside fellow Reliability Engineer Dave Daly as they problem solve for customers.

Tom began his wide-ranging career as a marine industry apprentice at Tilbury Docks in Essex before spending nearly 30 years in maintenance, supervisory, planning and scheduling and reliability roles with Cargill, a global firm providing food ingredients and systems essential to food production.

He said:“I’ve always wanted to know how things work, what’s wrong and how to fix them. I get a real buzz from problem solving and I’m very methodical. I’ve always been interested in promoting

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Working on site at the Warrington plant of customer Novelis is Fletcher Moorland Reliability Engineer Tom Hughes, right. He is pictured discussing a lubrication schedule for the Bag House fan with Novelis Electrical Reliability Engineer Ashley Thomas. reliability as well and I’m now getting the chance to do that here.

“For me it’s about improving something and because I’ve got a background in repair, I know what can break so I’m already at the next level.

I think if it’s not broken, improve it.”

Fletcher Moorland has an exclusive repair contract with Warrington-based Novelis, the world’s largest recycler of aluminum. They recycle 40 billion used drinks cans globally every year.

Novelis Electrical Reliability Engineer Ashley

Tom and Ashley analyse the vibration data from a shredder motor.

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Thomas said: “Fletcher Moorland repair all our rotating machinery. If we have a failure we send it to them and they also provide on site labour.

“We’ve worked closely with Dave and Tom to improve our lubrication schedules and maintenance regime and have now moved from being reactive to predictive and more planned maintenance.

“Since the contract started, catastrophic and major breakdowns have reduced so we’re now in a much better place.”

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Head of Research and Development Ken McCleaft digitally generates a new PCB using CAD technology,

Technical Director Geoff Rigby checks that a new PCB is correct before starting to lay out components.

PCB design and manufacture is proving a major cost saver ESEARCH and Development experts at Fletcher Moorland are using PCB design and manufacturing to save customers thousands of pounds on their machinery and equipment bills.

Having obsolete PCBs in control equipment is never an ideal situation to be in when you are responsible for keeping production machinery running. That is why Fletcher Moorland has set-up a specialist division to manufacture PCBs using the original obsolete ones as templates.

This can generate a massive cost saving benefit for customers – who don’t have to buy new machines when an outdated and faulty PCB needs repairing.

Ken McCleaft, Head of the Research and Development Division, said:“We deal with a whole range of customers from the Ministry of Defence to mining and transportation companies and small engineering firms.

“The process we employ means that even though a PCB may be classed as obsolete we can rebuild it from scratch and therefore save the customer a big bill in buying new machinery.

“They can then go on for years to come, operating the equipment and giving them

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even better value for money.”

The complex process of reverse engineering is broken down into several steps. This includes examining the sample board to catalogue the components that need replacing and a meticulous schematic capture stage to create an electronic diagram.

Engineers look at which modern-day components can be used to replace obsolete items, PCB foot printing is carried out and later in the process the whole board is digitally generated using a CAD system.

Later the PCB is laid down in copper and populated with components before being rigorously tested.

Ken said:“This can be quite complex and can take up to several weeks to complete depending on the PCB – but it can be invaluable to our customers.

“We worked with one particular company that was looking at a cost of £10 million to retool, however we were able to save them this money through reverse engineering PCBs, which kept their existing equipment running.

“We have seen a steady increase in this type of work over the last 12 years and more recently it has become much more frequent.

A replacement PCB designed and manufactured

by Fletcher Moorland.

“This is why we have set up a dedicated arm to deal with it. I can see it continuing to expand particularly as more and more companies become more automated and will see this type of back up service as essential.”

Fletcher Moorland news

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FM 06_07

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Drives and Controls Production Co-ordinator Lisa Rowe in the electronic workshop.

Pinpoint Diagnostics Engineer Kev O’Reilly tests components on a hydraulic card valve.

24/7 service galvanises position as top automation specialists 24/7 approach to repair and refurbishments – led by a team of experienced engineers – is helping Fletcher Moorland expand its customer base around the UK and galvanise its position as one of the leading industrial automation specialists.

A 23-strong team works on a range of industrial electronic devices including servo drives, inverters, power supplies, DC drives, temperature controllers, PLCs, HMIs and motion controllers.

Adopting a no-nonsense approach when a repair is required, one of Fletcher Moorland’s transport team will be dispatched – whatever the time of day or night – to bring the item back to the company’s state-of-the-art workshops.

Then a series of tests will be run to diagnose faults before remedial work is carried out. Ageing components and parts are also replaced as a matter of course to help improve longevity and thermal conductive paste used to heat-sync all the components.

All items are then tested with one of more than 1,000 test rigs Fletcher Moorland has on site. These have been specially-designed by the engineering teams to put the full array of parts and

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components that are repaired through their paces.

Finally the item is transported back to the customer with a 12-month warranty on the work that is done, offering further peace of mind.

Often the items that come in for repair are old and long-obsolete.

Fletcher Moorland engineers have to work without schematics to replace obsolete components or retrofit units in order to find a solution for the customer.

Lisa Rowe, Fletcher Moorland’s Drives and Controls Production Co-ordinator, said: “Our 24/7 approach is key to our business and really gives us an advantage. Any down time can be critical to our customers so it can be a case that a 3am call is taken and we have to act fast.

“When an emergency job comes in it is all hands to the pump to turn it around. To send a same day courier to collect parts needed for an emergency repair whatever the distance is a normal day at FML. “Our customers really value that commitment because it can save them thousands of pounds in downtime.

They respect the level of service and the experience we can bring to any repair or refurbishment.”

Bench Engineer Chris Rigby tests a SICK PLS sensor after repair.

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INVESTING TO STAY AT THE

CUTTING major investment in equipment and training is keeping the Servo Repairs Department at the cutting edge of its field. All-encompassing mechanical, electronic and electrical skills are required to make sure the sophisticated motors are returned as good as new – or even better than the day they rolled off the production line.

But as the servos being manufactured become more and more complex, Fletcher Moorland has moved fast to raise its game too. Servo Motor Repairs Manger Alan Palmer said:“New investment and training is vital because manufacturers are now producing servos which are more complex and sophisticated and becoming more and more software controlled. They don’t just plug and play.

“Carrying out testing, diagnostics and repairs, therefore requires a very high level of knowledge from our team here. We have committed to this because we know it puts us ahead of the game and builds reliability and confidence with our customers. That is why

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Servo Motor Repairs Manager Alan Palmer with a selection of motors. they turn to us with their repairs.”

The Servo Repairs team works with customers from a range of industries and a typical repair can take anything from a day to a few weeks depending on the complexity of the job. Fletcher Moorland servo repairs team has expertise in the electrical, electronic and mechanical sectors. All three of these skills are needed to offer a true servo motor repairs service. Over 50 per cent of the servo motors the company repairs require mechancial refurbishment such as new shafts, brake overhauls and bearing-fit refurbishments –

along with the expected encoder programing and alignment need with modern complex servo motors.

One of the ongoing orders being carried out by the Fletcher Moorland team is the refurbishment 66 Kawasaki servo motors used in Toyota’s paintshop department at Derby to ensure they pass rigorous testing required by the leading car manufacturer.

Alan added: “Our approach is to return the servo motor not only repaired or refurbished but as good as the day it was first installed on the production line.”

An encoder disc is refitted on an Allen Bradley motor.

Servo Technician Adam Locastro puts a Siemens motor through its paces on a test rig after repair and refurbishment.

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Top tyre factory ‘never let down’

Food firm finds the missing piece in maintenance jigsaw EADING food manufacturer Wrights Pies see Fletcher Moorland as the missing piece in the jigsaw when it comes to repairing broken down machines.

Loss of production at the company’s headquarters at Crewe can be critical, so every second counts when it comes to repairs.

John Mason, Engineering Supervisor at Wrights Pies, said: “Fletcher Moorland carries out all critical repairs on several machine lines at the factory, working on everything from electrical components to servo drives to mechanical breakdowns as well.

“Their 24/7 approach really helps me because we are an around the clock operation too. At weekends we carry out a 48-hour maintenance programme so if something is found to be in need of repair it is great to know that I can call Fletcher Moorland to fix it straight away.

“We have only been working together for a few months but I feel as if I have found the missing piece in our maintenance and repair jigsaw.”

Besides being a major UK food supplier, Wrights Pies exports its products around the world. Its range of ready meals has been a fast expanding addition to the business.

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MICHELIN has had a long-standing relationship with Fletcher Moorland whose services for the tyre manufacturing giant include repairing and refurbishing everything from pumps to motors and, most recently, printed circuit boards and touch pads.

Kevan Williams, RS Tec, based at Michelin’s factory in Stoke-on-Trent, said:“There are two areas in which we work with Fletcher Moorland. Firstly, they refurbish older items for us as part of our standard recuperation circuit, so when we have a spare unit we can send it to them for restoration.

“The other service they provide is emergency repair when we have a breakdown. This is a service which is provided on a 24/7 basis and is essential in helping me ensure our factory keeps operating around the clock. Fletcher Moorland has supported us in these aspects for many years and we have never been let down by their level of service or ability to respond.”

Solutions have saved money A company which operates the deepest mine in the UK to produce potash for fertilizer is benefitting from Fletcher Moorland expertise. Cleveland Potash, based in Saltburn-by-the-Sea, north of Whitby, works closely with Fletcher Moorland who design and manufacture control equipment used on underground mining machines.

Other work includes repairing and refurbishing Cleveland Potash’s explosion-proof motors.

Stuart Nielson, Production Electrical Engineer for Cleveland Potash, said: “Currently they repair our flame-proof mining motors as well as carrying out repairs and testing on our Miner DC traction drive modules.

“However the main benefit to ourselves, is that their electronics engineers have been able to re-engineer several devices and systems that have become obsolete.

Without these parts we would have lost the production capability of several of our operating machines.

“Fletcher Moorland’s expertise has enabled us to save money with engineering solutions.”

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Fletcher Moorland news

One of the production lines at Wrights Pies’ Crewe plant.

First-class operations ‘more than a repair shop’ ERLSON Precision Components, a Skelmersdale-based automotive parts manufacturer employing 240 staff, uses Fletcher Moorland’s expertise to support its own team of technicians looking after 200 CNC machines and specialist robotic equipment.

Mark Corns, Director Technical Services, said: “Ever changing demands in the work environment and the need for effective and responsive 24 hour maintenance meant it was vitally important to underpin our own dedicated maintenance

team with something more than just a sub-contract repair service. After seeing the first class Fletcher Moorland operations in Stoke, it was apparent that they are more than just a repair shop.

“Their dedicated, highly skilled technicians carry out specialised repairs, give us on site fault diagnosis and support our team of technicians. Their responsive technical support is now a vital and key part of our onsite maintenance support.”

WORK ETHOS SUITS EXCAVATOR GIANT GLOBAL excavator giant JCB uses Fletcher Moorland to repair a range of older and modern equipment, usually on emergency service for a quick and immediate turnaround with a two year warranty.

The work is carried out at JCB’s World HQ in Rocester as well as other manufacturing plants in North Staffordshire.

A JCB spokesman said: “The Fletcher Moorland ethos of improving equipment from the original spec and warranties after repair fits in perfectly with our strong culture of root cause analysis and continuous improvement.”

Repairs are quick and thorough

Precision tools and components being manufactured at PTG Holroyd in Rochdale.

PTG Holroyd is an industry-leading manufacturer of highly engineered precision machine tools and components for a range of diverse industries around the world.

Fletcher Moorland repairs a number of the Rochdale-based company’s machines – which are used in the manufacture of precision engineered helical rotors and screws.

PTG Holroyd Site Services and Maintenance Manager Simon Clark said:“Quick and thorough repairs to our machines are absolutely essential as any down time is critical to our business.

“Fletcher Moorland responds quickly to a breakdown, they will come and collect machine parts needing repair and have them back on site and up and running as soon as possible. No issue is too big or small and there is never any hesitation when a repair is required. We have what I would call a true partnership relationship.”

Part of the Backhoe Loader production line at the JCB World HQ.

Support for more than a decade COVENTRY-BASED automotive component manufacturing company UYT Limited has been supported by Fletcher Moorland for more than 10 years – with repairs for Fanuc and Nachi drives and servo motors, robotic equipment and main press motors.

Maintenance Manager Martin Goater said:“In 2007, during the two week summer shutdown, we removed, refurbished and refitted every servo motor in the press shop, from Reliance transfer servo motors up to 132KW Thrige Scott DC Press Main Motors.

“To date, we’ve had no motor failures in the press shop since carrying out this exercise. This year we plan to repeat this exercise by using in situ testing and monitoring in an effort to reduce costs.

“Fletcher Moorland has also supported us with on-site breakdown repair and diagnosis on a Mitsubishi 75KW Inverter which was subsequently repaired and tested. Moving forward, I have approached Fletcher Moorland about fitting vibration analysis equipment to provide early diagnosis of potential failures.”

Fletcher Moorland news

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FM 08_09

12/3/15

16:32

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Top tyre factory ‘never let down’

Food firm finds the missing piece in maintenance jigsaw EADING food manufacturer Wrights Pies see Fletcher Moorland as the missing piece in the jigsaw when it comes to repairing broken down machines.

Loss of production at the company’s headquarters at Crewe can be critical, so every second counts when it comes to repairs.

John Mason, Engineering Supervisor at Wrights Pies, said: “Fletcher Moorland carries out all critical repairs on several machine lines at the factory, working on everything from electrical components to servo drives to mechanical breakdowns as well.

“Their 24/7 approach really helps me because we are an around the clock operation too. At weekends we carry out a 48-hour maintenance programme so if something is found to be in need of repair it is great to know that I can call Fletcher Moorland to fix it straight away.

“We have only been working together for a few months but I feel as if I have found the missing piece in our maintenance and repair jigsaw.”

Besides being a major UK food supplier, Wrights Pies exports its products around the world. Its range of ready meals has been a fast expanding addition to the business.

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MICHELIN has had a long-standing relationship with Fletcher Moorland whose services for the tyre manufacturing giant include repairing and refurbishing everything from pumps to motors and, most recently, printed circuit boards and touch pads.

Kevan Williams, RS Tec, based at Michelin’s factory in Stoke-on-Trent, said:“There are two areas in which we work with Fletcher Moorland. Firstly, they refurbish older items for us as part of our standard recuperation circuit, so when we have a spare unit we can send it to them for restoration.

“The other service they provide is emergency repair when we have a breakdown. This is a service which is provided on a 24/7 basis and is essential in helping me ensure our factory keeps operating around the clock. Fletcher Moorland has supported us in these aspects for many years and we have never been let down by their level of service or ability to respond.”

Solutions have saved money A company which operates the deepest mine in the UK to produce potash for fertilizer is benefitting from Fletcher Moorland expertise. Cleveland Potash, based in Saltburn-by-the-Sea, north of Whitby, works closely with Fletcher Moorland who design and manufacture control equipment used on underground mining machines.

Other work includes repairing and refurbishing Cleveland Potash’s explosion-proof motors.

Stuart Nielson, Production Electrical Engineer for Cleveland Potash, said: “Currently they repair our flame-proof mining motors as well as carrying out repairs and testing on our Miner DC traction drive modules.

“However the main benefit to ourselves, is that their electronics engineers have been able to re-engineer several devices and systems that have become obsolete.

Without these parts we would have lost the production capability of several of our operating machines.

“Fletcher Moorland’s expertise has enabled us to save money with engineering solutions.”

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Fletcher Moorland news

One of the production lines at Wrights Pies’ Crewe plant.

First-class operations ‘more than a repair shop’ ERLSON Precision Components, a Skelmersdale-based automotive parts manufacturer employing 240 staff, uses Fletcher Moorland’s expertise to support its own team of technicians looking after 200 CNC machines and specialist robotic equipment.

Mark Corns, Director Technical Services, said: “Ever changing demands in the work environment and the need for effective and responsive 24 hour maintenance meant it was vitally important to underpin our own dedicated maintenance

team with something more than just a sub-contract repair service. After seeing the first class Fletcher Moorland operations in Stoke, it was apparent that they are more than just a repair shop.

“Their dedicated, highly skilled technicians carry out specialised repairs, give us on site fault diagnosis and support our team of technicians. Their responsive technical support is now a vital and key part of our onsite maintenance support.”

WORK ETHOS SUITS EXCAVATOR GIANT GLOBAL excavator giant JCB uses Fletcher Moorland to repair a range of older and modern equipment, usually on emergency service for a quick and immediate turnaround with a two year warranty.

The work is carried out at JCB’s World HQ in Rocester as well as other manufacturing plants in North Staffordshire.

A JCB spokesman said: “The Fletcher Moorland ethos of improving equipment from the original spec and warranties after repair fits in perfectly with our strong culture of root cause analysis and continuous improvement.”

Repairs are quick and thorough

Precision tools and components being manufactured at PTG Holroyd in Rochdale.

PTG Holroyd is an industry-leading manufacturer of highly engineered precision machine tools and components for a range of diverse industries around the world.

Fletcher Moorland repairs a number of the Rochdale-based company’s machines – which are used in the manufacture of precision engineered helical rotors and screws.

PTG Holroyd Site Services and Maintenance Manager Simon Clark said:“Quick and thorough repairs to our machines are absolutely essential as any down time is critical to our business.

“Fletcher Moorland responds quickly to a breakdown, they will come and collect machine parts needing repair and have them back on site and up and running as soon as possible. No issue is too big or small and there is never any hesitation when a repair is required. We have what I would call a true partnership relationship.”

Part of the Backhoe Loader production line at the JCB World HQ.

Support for more than a decade COVENTRY-BASED automotive component manufacturing company UYT Limited has been supported by Fletcher Moorland for more than 10 years – with repairs for Fanuc and Nachi drives and servo motors, robotic equipment and main press motors.

Maintenance Manager Martin Goater said:“In 2007, during the two week summer shutdown, we removed, refurbished and refitted every servo motor in the press shop, from Reliance transfer servo motors up to 132KW Thrige Scott DC Press Main Motors.

“To date, we’ve had no motor failures in the press shop since carrying out this exercise. This year we plan to repeat this exercise by using in situ testing and monitoring in an effort to reduce costs.

“Fletcher Moorland has also supported us with on-site breakdown repair and diagnosis on a Mitsubishi 75KW Inverter which was subsequently repaired and tested. Moving forward, I have approached Fletcher Moorland about fitting vibration analysis equipment to provide early diagnosis of potential failures.”

Fletcher Moorland news

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Service makes the refurbished better than new EPAIR and refurbishment standards in the Fletcher Moorland Electro-Mechanical Workshop are so high that equipment is returned to customers in a better working condition than the original new unit.

A team of up to 30 fitters, machinists and winders provide round-the-clock repair and reclamation services on and off-site.

The state-of-the-art workshop uses industry-leading testing equipment and a range other machinery including centre lathes, milling machines, balancing machines and fully automated coil winding machines.

Led by Electro-Mechanical Workshop Manager Matt Sparkes, a Fletcher Moorland stalwart for 16 years, they take great pride in their work as they fix anything from AC and DC motors, pumps, fans and gearboxes.

The workshops cater for equipment up to 10 tonnes in

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Engineer John Thornhill assembles a motor used on a train.

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weight and up to one megawatt capacity. Matt said:“We repair and refurbish rotating equipment and believe that every item that leaves our workshop goes back to our customers in a better condition than when it was new.

“What sets us apart is our attention to detail and exacting engineering standards.

“For instance we carry out dynamic balancing to G1 which is two grades higher than the standard OEM 6.3. We even use a computer-controlled machine to measure bearing fits down to one micron – a thousandth of a millimetre. This is important because over half of motor failures are bearing related and getting it right at the refurbishment stage ensures longer life. We always go above and beyond. It’s just second nature to us.

“All our repairs and refurbishments come with a minimum 12 months warranty.”

Electro-Mechanical Workshop Manager Matt Sparkes uses a dial test indicator to check lift in a bearing arrangement on a backwash filter.

A repaired and refurbished KSB Ex pump ready to be returned to a customer.

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“”

We’re really proud of the quality of our work in this very sensitive area.

IAN CHADWICK EX RESPONSIBLE PERSON

Ex Responsible Person Ian Chadwick carries out final quality checks on an Ex motor. Above left, The Fletcher Moorland IECEx stamp on an Ex motor showing it has been repaired to the strict standards required by the IEC.

Ex motors are repaired to strict certified standards XPLOSION-PROOF motors are repaired and overhauled at the company’s Elenora Street base to strict, certified standards IEC60079:19 – Fletcher Moorland being the only company in the region to have IECEx Certified Service Facility accreditation. Ex motors, as they are known, are used in any area of a factory or plant with the potential to have an explosive atmosphere from flammable substances like gases, vapours, mists or dusts. The IEC (International Electrotechnical Commission) issues IECEx repair licenses only after stringent audits

by Ex Notifying Bodies.

Seven people who work in the FML Electro-Mechanical Service Centre including Ex Responsible Person Ian Chadwick have undergone specialist training and are certified to IECEx standard to carry out Ex motor repairs.

Ian said: “A series of mining disasters with the loss of hundreds of lives in the early 20th Century first led to the introduction of flameproof equipment standards and the development of explosion-proof motors.

“Ex motors are specially designed and certified to contain any internal ignition should they fail during operation and prevent the surrounding atmosphere from being ignited. Ex motor repairs are strictly regulated and have to be carried out to the most exacting standards because the consequences of an improperly repaired or refurbished Ex motor in a mine or a petro-chemical plant could be disastrous.

“Our working practices when repairing Ex motors are continually audited by an external Ex Notifying Body and we’re really proud of the quality of our work in this very sensitive area.”

Fletcher Moorland’s certificate covers Ex (e), Ex (d), Ex (tD), Ex (n) and Ex (c) equipment.

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Ian Chadwick shows the coveted IECEx accreditation certificate.

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Family connections at Fletcher Moorland, front row left to right, Zach Horrobin, Denise Hargreaves, Maddie Greatbatch and Jean Fletcher; second row, Lisa Rowe, Matt Fletcher, Dan Mansell, Diane Mansell, Malcolm Fletcher; third row, Chris Rigby and Geoff Rigby; back row, Matt Sparkes, Steve Robson, Jon Rowe, Phil Robson, Joe Mansell, Kev Bradshaw and Andy Mansell.

A real family business T really is a family affair at Fletcher Moorland. Husbands and wives, fathers and sons, aunties and nieces, brothers, uncles and even a fiancé and his bride-to-be work hand in hand in roles from management to sales and from accountancy to apprenticeships.

But there is much more to the number of close ties than just sheer coincidence.

Throughout its 70-year history, Fletcher Moorland has always been a family-run business and actively encourages the participation of family members within the workforce.

These values are passed on from one generation to the next – which helps to engender honesty and loyalty and the continuation of the company.

Operations Director Diane Mansell said: “Fletcher Moorland is no different from most companies – we have an ageing yet

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skilled workforce. The introduction of family members taking on various roles can help to ensure the longevity of the business within the repairs and service industry.

“There is truly a family friendly environment throughout Fletcher Moorland. I can speak personally on this subject since I have introduced members of my own family too.”

The family ties within the 72-strong workforce are many a varied, here’s how they currently pan out: Managing Director Matt Fletcher is the son of Director and former MD Malcolm Fletcher whose wife Jean is a Director with special responsibility for accounts.

Operations Director Diane Mansell is married to Sales Manager Andy Mansell.

Their son Joe Mansell works as an Electro Mechanical Apprentice and his brother

Dan is a Purchasing Apprentice.

Meanwhile, Diane’s niece, Maddie Greatbatch, is also employed as an accountant.

Electro Mechanical Workshop Manager Matt Sparkes is engaged to Receptionist Denise Hargreaves and they will be tying the knot later this year.

Area Sales Manager Jon Rowe is married to Drive and Controls Production Co-ordinator Lisa Rowe.

Brothers Steve and Phil Robson are both Electro Mechanical Engineers while Kev Bradshaw, also an Electro Mechanical Engineer, is uncle to Electro Mechanical Apprentice Zach Horrobin.

Finally… for now anyway because there are new people being recruited all the time –Technical Director Geoff Rigby is the dad of Drives and Controls Engineer Chris Rigby.

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Apprentices go BACK TO THE FUTURE HREE apprentices have gone back to the future as they carry out a six-month project to restore an iconic Sinclair C5 bought by Managing Director Matt Fletcher for just £50.

Joe Adams from Drives and Controls, Machinist Joe Mansell and Fitter Zach Horrobin spend one afternoon a week working on the three-wheeled road-going vehicle once voted the worst invention of all time. Led by Drives and Controls Engineer Joe Oakden, they are giving it a complete tyre-up overhaul as the wiring, the motor, drive system and chassis are completely upgraded in line with the Fletcher Moorland ethos of improving components.

Project leader Joe, who has been with Fletcher Moorland for four

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years, said:“We get together on a Wednesday afternoon to swap ideas on what we need to do and share out tasks. The idea is to give our apprentices practical applications for their theory and it’s good for them to experience the skills of other departments. It creates that inter-departmental family feeling.

“They’re learning team work, new skills and how to report back as they keep Matt up to date on progress. It’s really interesting and enjoyable. The C5 didn’t have any speed calibration so we’re sorting that out and hope to double its top speed from 15 to 30 miles an hour.”

Training to help frontline fault finding FLETCHER Moorland is now offering apprentice training to customers to help them with frontline fault finding on electric motors and inverters. The skills being taught are not generally covered in mainstream apprentice training.

Designed to meet the specific needs of each client, they can send their staff to Stoke-on-Trent for the training which covers AC and DC motor theory, inverter operation, practical use, set up, strip down and diagnostic testing.

For more information contact Operations Director Diane Mansell on 01782 411021 or email on diane@ fletchermoorland.co.uk.

Drives and Controls Engineer Joe Oakden, standing, with apprentices, left to right, Zach Horrobin, Joe Adams and Joe Mansell working on the Sinclair C5.

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Win single malt whisky in our

components conundrum E

NTER our eagle-eyed engineering quiz to be in with the chance of winning a bottle of single malt whisky worth more than ÂŁ100.

Study the eight photographs on this page – which are all shots of engineering components, and try to identify what they are.

All items pictured are parts seen everyday in the equipment repaired and serviced in the Fletcher Moorland workshops.

Send your answers to the components conundrum challenge by email to quiz@fletcher moorland.co.uk by the end of September this year. Please include a daytime contact number.

Entries will be drawn out of the hat in early October with the lucky winner receiving a bottle of single malt whisky from Managing Director Matt Fletcher. Runners up prizes will also be awarded.

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D C

E

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F 14

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Founder Sam Fletcher pictured in 1955 with a company van.

Company set to celebrate its

70TH ANNIVERSARY LETCHER Moorland will be celebrating its 70th anniversary next year by continuing to invest in its core business ethos – providing quality work and exceptional customer service.

It was in 1946 that Electrical Engineer Sam Fletcher founded a partnership, Electrical Rewinds and Supplies, to repair and rewind electric motors mainly for industries in North Staffordshire including pottery factories, coal mining, steelworks and tyre manufacturing.

Since then two successive generations, Sam’s son Malcolm and grandson Matt, have overseen the company’s growth and diversification to become one of the UK’s leading players in electro-mechanical and electronics repair and maintenance with a national and international reputation for reliability and innovation.

“My father put great emphasis on looking after his customers and ensuring the work was done to the highest possible quality – a philosophy which has been passed on and which has stood the company in good stead over the decades,” said Malcolm, who became Managing Director 37 years ago in 1978.

“To keep a business going for 70 years you continually have to adapt and stay ahead of the game – there is no time to rest on the laurels of the past. We have always invested in the very latest technology and developing the skills of our engineers – and this is something we will keep doing going forward.

“We are continuing to expand and find new markets for our specialist skills. Our culture of hard work and customer service is reflected in our commitment to providing a genuine

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“” Former MD Malcolm Fletcher who himself reaches a notable milestone next year. round-the-clock, 365 days a year service.”

Next year also brings a notable milestone for Malcolm – 50 years since he joined the business full-time after completing an apprenticeship at English Electric in Stafford.

He was succeeded as MD by his son Matt six years ago.

Fletcher Moorland is planning to mark its

To keep a business going for 70 years you continually have to adapt and stay ahead of the game...

70th birthday by holding a series of events including an open day for customers, staff past-and-present and people who have been associated with the company over the years.

Malcolm added:“I am very proud that we are still an independent, family-run business with the third generation at the helm overseeing exciting developments and growth.”

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