The NXV1020A is our third on shopfloor and will incorporate one of the two Nikken 4 axis we have.

Rapid tool changing in 1.8 seconds and a 12,000 rpm spindle assist us in manufacturing precision aluminium parts at a competitive price.

We’ve specified with Heidenhain control to match our six other machining centres.

As always we’re grateful to YMT for their support, swift installation and delivery.

Fingers crossed to another 18 years from this one..!

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At Presto  we understand how  high end audio design  combines technology and aesthetics to achieve the desired end product. Presto  have the expertise and specialism  required to produce consistent parts that are  required for the high end audio market.  We take responsibility for all aspects of your machining  from submission of the drawing to on time delivery of your components with a pristine finish.

We offer a range of finishes and the application of the product usually determines the choice of finish.  For visible Precision Machined Audio Components  where appearance is key, aluminium lends itself to stylish finishes such as anodising and wet paint. At Presto we take the dimensional accuracy and visible finish of our parts very seriously. When it comes to visible parts they are 100% checked prior to and after the finishing process.

We pride ourselves on the relationships that we’ve built with our customers. They tell us that our attention to detail is ‘second to none’. Whatever your requirements  we work with you to find the best solution for your hight end audio product.

Could Presto’s expertise help you?
If you’d like to find out more about Presto Engineering contact us to discuss  your  precision engineering requirements.
01865 883508        sales@prestoeng.co.uk

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Extrusion is defined as the process of shaping material. In this case aluminium, by forcing it to flow through a shaped opening in a die.  Extruded material emerges as an elongated piece with the same profile as the die opening.  The extrusion process makes the most of aluminium’s durability, flexibility and light weight.  Its malleability allows it to be easily machined and cast. Aluminium is one third the density and stiffness of steel so the resulting products offer strength and stability.

Why use Aluminium Extrusion?

The aluminium extrusion process provides almost unlimited opportunities to the product designer with the added benefit of low tooling costs and short lead times.  Components can be designed to incorporate extra features that provide fixings, channels and interlocking systems that preclude the need for additional parts.  These features can even be incorporated so that they enhance the structural strength of the assembly.

The use of  extrusions in combination with novel fabrication techniques can be a low cost tooling solution.  The prototype costs can be reduced during design and the manufacturing technology is easily transferred into full production.

It is not just in new product design where the benefits of aluminium extrusions can be appreciated.    In existing products the substitution of other materials and processes with aluminium extrusions can result in cost saving through fewer components, reduced finishing, simplified assembly and improved supply chain logistics.

The Extrusion Process

There are two main methods of extrusion – direct and indirect.  Direct extrusion is the most frequently used  whereby the die head is held stationary and the aluminium billet is forced through the die using a moving ram.  In indirect extrusion, the aluminium billet is held stationary and the ram moves the die to exert pressure in the stationary billet.

Direct extrusion is commonly used in the manufacture of solid rods, bars, and hollow tubes. The design of the die can be modified to produce a wide variety of solid and hollow profiles.

The material for making extrusions is the aluminium log.  These are cast in lengths of up to 7 metres and available in a wide range of alloys and diameters.  After casting they are further heat treated (homogenised) before being supplied to the customer.

The first operation is to cut the long extrusion log into suitable lengths for extrusion based on press capacity and the final extruded length which is typically 400mm to 1000mm.  The cut log (or billet) is fed into the billet heater where it is heated to 400-500^oC.  The exact temperature will depend on the alloy shape, complexity and other process parameters.

Extrusion involves pressing a preheated  ingot (450-500^oC) under high pressure (1600-6500 tons depending on the size of the press) through a die the opening of which corresponds to the cross-section of the extrusion.  In the traditional direct method of extrusion the die is stationary.  The length may be as long as 50 metres and may consist of one strand or multiple strands of the same section.

The extrusion is cut and moved along the cooling table.  When cooled it is  moved to the stretcher which straightens the extrusion and performs ‘work hardening’ or molecular re-alignment which gives it increased hardness and improved strength.

Some of the benefits of using Aluminium Extrusion

In general and extrusions in particular, offer a number of benefits relative to alternative materials and processes including:-

Lightweight 

Aluminium is about 1/3 the weight of iron, steel, copper or brass. Making  extrusions easier to handle, less expensive to ship, and an attractive material for use in applications where weight reduction is a priority such as transportation and other applications involving moving parts.

Strong

Aluminium extrusions can be made as strong as needed. Due to the nature of the extrusion process, the strength can be concentrated where it is rquired by including varying wall thicknesses and internal reinforcement in the profile design.  Cold-weather applications are particularly well served by extrusions, as it becomes stronger as temperatures fall.

High in strength-to-weight ratio

Aluminium extrusions unique combination of high strength and low weight makes them ideal for applications like aerospace and bridges where load carrying is a key performance.

Resilient

Aluminium combines strength with flexibility, and can flex under loads or spring back from the shock of impact, leading to the use of extruded components in automotive crash management systems.

Corrosion resistant

Aluminium extrusions offer excellent corrosion resistance.  They do not rust, and the aluminium surface is protected by its own naturally occurring oxide file, a protection that can be enhanced by anodizing or other finishing processes.

Quick-to-market

Tooling is relatively inexpensive with generally short lead times, facilitating swift prototype development, testing, and product launch.

Easy to fabricate & assemble

Effective design can greatly simplify subsequent fabrication and assembly, and there are a wide variety of fabrication processes that are routinely employed in the production of extrusion-based components and assemblies.

Sustainable

Aluminium can be recycled with no degradation in properties. Aluminium extrusions are often produced with high recycled content without compromise to aesthetics or functionality.

Contact

If you would like further information on Aluminium Extrusion or any other topic relating to CNC milling of aluminium machined components please get in touch at sales@prestoeng.co.uk.

For more information about Presto Engineering please visit our website here and if you would like a quote or to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

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Aluminium Finishing- At Presto we take responsibility for all aspects of your project from submission of drawing to on time delivery of your components with a pristine finish.

We offer a range of finishes and the application of the product usually determines the choice of finish.  For visible parts where appearance is key aluminium lends itself to stylish finishes such as anodising.  Durability is often a deciding factor particularly when parts are for outdoor use.  When parts will not be visible and are for indoor use they can have a range of cost effective treatments such as Surtec 650, Alochrom or Irridite.  Whatever your requirements we work with you to find the best solution for your component.

Below are a selection of finishes we offer:-

 Anodising

Anodising can only be carried out on aluminium and it is the most frequently requested finish by our customers.  It is an electrochemical process that converts the metal surface into a decorative, durable corrosion-resistant anodic oxide finish and can be dyed in a variety of colours and finishes.

Anodising is accomplished by immersing the aluminium into an acid electrolyte bath and passing an electric current through the medium.  A cathode is mounted to the inside of the anodising tank; the aluminium acts as an anode so that oxygen ions are released from the electrolyte to combine with the aluminium atoms at the surface of the part.  In brief, anodising is a matter of highly controlled oxidation which is an enhancement of a naturally occurring phenomenon.

Benefits of Anodising include:-

Durability – Most anodised products have a long life span so the finish needs to be durable.  Anodising is a reacted finish that is integrated with the underlying aluminium for total bonding and unmatched adhesion.  The anodised surface is very hard and as a result preserves and extends the life of the aluminium product.  Anodised aluminium is resistant to corrosion and well suited to a wide range of applications.

Colour Stability – The sealing process used in anodising results in your anodised part looking factory new for years.  Anodised surfaces provide good stability to ultraviolet rays, do not chip or peel and are easily replicated.

Ease of Maintenance – Scars and wear and tear from handling, installation, frequent cleaning and usage are virtually non-existent.  It is generally sufficient to clean anodised surfaces with mild soap and water to maintain the original finish although a mild abrasive cleaner can be used for more stubborn stains.

Aesthetics – Anodising offers a wide variety of colour and texture alternatives and allows the aluminium to maintain its metallic appearance.

Cost – A low initial finishing cost combined with minimal maintenance costs makes anodising excellent long term value.

Health and Safety – As the anodising process is a reinforcement of a naturally occurring oxide process, it is non-hazardous and does not produce any harmful or dangerous by-products.

Anodising Pre-Treatments

• Bead Blasting

Bead blasting is the process of removing surface deposits on metal by applying fine beads at high pressure using compressed air without damaging the surface.  It is a popular choice of finish with our customers and we have invested in new Bead Blasting and Graining equipment.

Machined aluminium parts end up with lines, swirls and etching on the surface as a result of the machining process.  To prevent these imperfections from translating through a coating or anodising the surface is always made uniform by bead blasting prior to applying the chosen finish.

The benefits of Bead Blasting include:-

Uniform Finish –A perfectly clean uniform finish is achieved on all shapes of component including 3D and curved.

Styling Options – By varying the bead size the surface finish can be altered to suit individual customer requirements.  The graining can be made coarser or finer and the finish matte or bright.

• Graining

Graining is the process of polishing ‘grit lines’ onto the surface that are uniform and directional in appearance.   It is achieved by polishing the surface with an abrasive grit belt.  The finish achieved will depend upon the coarseness of the grit used.  Graining followed by clear anodising will result in a natural finish.  This finish is particularly popular for trims and badges.

Industrial Paint Finishes 

There are two systems of industrial paint finishes for aluminium finishing; wet painting and powder coating. Both of these systems will offer a durable and corrosion proof coating, but the application of the component will determine which system is used.

• Wet Paint

Generally speaking wet painting is used where a durable high quality finish is required on visible surfaces that the end user comes into contact with. For example applications can range from machined front panels for high end audio equipment through to car bodywork. Finishes are wide and varied and range from high gloss through to matte, and there is also the ability to have soft feel rubberised and suede textures incorporated.

Wet paint is commonly applied using a spray painting method, which involves utilising an air-pressurised spray gun. The air gun is made up of three main parts; the nozzle, paint basin and air compressor.  Paint is mixed with compressed air and when the trigger is activated a fine spray is released.  Usually a coating will be applied by hand, although the process can also be automated.

• Powder Coat

Powder-coating also provides a very hard wearing and durable coating.  It is ideal for products that are subject to intense handling or products that do not require such a high quality finish.  A multitude of coatings can be specified such as satin, gloss, metallic, iridescent and matte.

Powder coat application is based on the principle of opposite electric charges being attracted to one another.  Powder particles are electrostatically charged as a result of passing through a charged spray gun and are then attracted to an earthed component. The part is then thermally cured in an oven and the result is a high resistance finish.

Screen Printing

Screen printing is used in Aluminium finishing to print text and colour graphics onto almost any component for example control panels, nameplates for machines, serial and model numbers etc.  It results in a durable print that cannot be scratched off easily and is resistant to corrosion and extremes of temperature and weather.

Anoprinting

Anoprinting is generally used for demanding applications such as industrial environments. The process of anodising opens up the pores of the aluminium, a printed dye is then introduced into the porous surface layer. The pores are then sealed, trapping the ink into the surface. It changes the chemical composition of the aluminium, forming a hardened layer which provides protection from corrosion, and increases resistance to wear and abrasion. The surface appearance is resistant to marking from fingerprints and makes for a functional and decorative label.

Laser Engraving

Laser engraving is a process  that is suitable for aluminium finishing it’s where a high heat laser beam physically removes the surface of the material by causing it to vaporise and creates a cavity.  If the metal has been pre-treated or coated, the laser will engrave away this top coating to reveal the metal finish below.  Engraving can be used to customise or personalise parts and is particularly good for high wear parts.

Laser Etching

Etching is a process where a laser beam uses high heat to melt the surface and the melted material expands and causes a raised mark.  It can be done on anodised or bare aluminium.

Laser Marking

Laser marking uses a lower power beam than laser engraving and etching and leaves the surface material intact.  It is achieved by moving a low powered beam across the surface which causes oxidation under the surface turning the material black.  The precise and repeatable nature of lasers allow for fine detail marking on small components.  Laser marking is used for identifying products for example bar codes, serial numbers and regulatory symbols.

The options for aluminium finishing are endless so please do call us on 01865 883508 or e mail us at sales@prestoeng.co.uk to discuss your project.

For more information about Presto Engineering please visit our website here and if you would like to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

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UK manufacturers are used to working in competitive markets as a result of Political events at home and overseas the UK faces a period of economic uncertainty.  It looks likely businesses will see raw material and component costs rise and the challenge will be delivering the same high quality products at a price the customer will pay.  Optimising product design for manufacture and assembly is a key contributor to managing costs and gaining a competitive edge.

As a manufacturer of machined aluminium parts we encourage our customers to involve us early in the design process.  It is well known that, although design costs consume approximately 20% of the total budget for a new project, typically 80% of manufacturing costs are determined by the design of the product¹.  However, the days of product design taking place in a vacuum are long gone!   Concurrent Engineering, a method of designing and developing products, in which the different stages run simultaneously, rather than consecutively, is the key to achieving a design suitable for cost effective manufacture and assembly.  Here are a few key points to consider²:-

Simplifying the design

Reducing the number of parts increases the probability of a perfect part, and reduces costs.  Fewer fabrication and assembly steps are required which gives the opportunity to integrate processes and reduce lead times.

Standardise and use common parts and materials

To minimise the level of inventory in the system and standardise handling and assembly operations.  An example of this in action is the VW Group³ chassis system which is used across a wide range of vehicles.  Known as the Modular Transverse Matrix (MQB)⁴ it is the standardisation of vehicle components and production processes and enables different models and brands to run on the same assembly line.

Design for ease of fabrication

Select materials compatible with production processes.  Working closely with Procurement colleagues can result in optimum material selection and sourcing at the best price.  Design for ease of fixturing and avoid unnecessary part features that involve extra processing effort and/or more complex tooling.

Design for easy and ‘mistake-proof’ assembly

By ensuring that the assembly process is unambiguous.  The ideal scenario is components that can only be assembled one way!  Threaded fasteners such as screws, nuts and bolts are time consuming to assemble and difficult to automate.  It is worth considering the use ‘snap-fit’ attachment methods.

Design for automated production

By ensuring that the product is easily assembled manually.  Automated production is less flexible and considerations vary depending on whether flexible robotic assembly or high speed automation is to be used.

As usual we would love to hear what you think?  Are you working closely with your designers?  Have your raw material and component costs risen since Brexit?  Please give us a call on 01865 883508 or e mail us at sales@prestoeng.co.uk.

For more information about Presto Engineering please visit our website here and if you would like to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

References   

¹Claudio Favi, Michele Germani, Marco Mandolim, 2016. Design for Manufacturing and Assembly vs. Design to cost: toward a multi-objective approach for decision-making strategies during conceptual design of complex products. [pdf] Available at: http://ac.els-cdn.com/S2212827116305741/1-s2.0-S2212827116305741-main.pdf?_tid=18f28f0a-ed44-11e6-a391-00000aab0f27&acdnat=1486478921_9a20816b1f8c938f9ffd5d9556be447f [Accessed 8 February 2017].

²NPD Solutions, 2014. Design for Manufacturability/Assembly Guidelines. [online] Available at: http://www.npd-solutions.com/dfmguidelines.html [Accessed 8 February 2017].

³Dr James Moultrie, University of Cambridge, 2015. A holistic view of design for manufacture [pdf] Available at:

http://www.ifm.eng.cam.ac.uk/uploads/News/2012/15_Feb_Design_Icons_event_comes_to_IfM/DfMevent15-2-12.pdf [Accessed 8 February 2017].

⁴Volkswagen UK, 2016. Modular Transverse Matrix MQB [online] Available at http://www.volkswagen.co.uk/technology/modular-transverse-matrix-mqb [Accessed 8 February 2017]

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Is the future of UK Manufacturing in Robotics and Automation?

In 2012 the UK was ranked 19^th worldwide in terms of Robot density in the manufacturing sector with a level barely above the global average.  As an example the UK automotive industry is functioning with half as many robots as used in Germany, often cited as the European gold standard bearer for automation¹.

How has the UK been left behind?  It boils down to a lack of investment compared to other developed economies and the Office of National Statistics (ONS) has stated that the UK’s lack of improvement in post war productivity is “unprecedented”².

Germany and Japan are highly automated in manufacturing and if the UK were at the same level it is estimated productivity would increase by as much as 22% and long term employment by 79%. BMW’s Mini Plant in Oxford and Jaguar Land Rover’s plants at Solihull and Halewood are examples of soaring productivity as a result of heavy investment in robotics and automation³. But they are not the general rule in UK manufacturing.  Bearing in mind this technology is open to all markets what must we do to increase our global competitiveness?

In this article the terms ‘Robotics’ and ‘Automation’ are used interchangeably as businesses will utilise the most effective technology to achieve their goal.

In late 2015 Barclays issued a report, ‘Future-proofing UK manufacturing’ based on economic analysis conducted on behalf of YouGov.  It includes results of a survey of UK and German manufacturers and, by the use of economic modelling, shows the potential future impact of investment in Robotics and Automation¹.  The ‘top line’ suggests that if the UK invested £1.24bn in robotics and automation over the next 10 years it could add £60.5bn to the economy¹.  But how do those statistics impact an average UK manufacturing business and what has stopped them investing in automation?

Some key barriers to investment identified are:-

• Lack of funds for short and long term investments
• Prioritising other capital investment projects
• Concerns over the level and time of ROI
• Lack of support and advice about making the decision to automate

The size of business impacts the number investing, for example:-

• 71% of businesses with a turnover >£10m have invested in Robotics and Automation
• 21% of businesses with a turnover <£1m have invested in Robotics and Automation

Finally the type of business impacted the level of investment.

Sample business sectors with higher levels of investment in Britain:-

• Heavy Industry
• Medical Devices
• Building Products
• Automotive and transport

Sample business sectors with lower levels of investment in Britain:-

• Printing and Packaging products
• Textiles and clothing
• Wood and paper products

The trend is for businesses to increase investment in the next 2-3 years with the focus on improving efficiency and output.  This includes reducing production time, improving quality and plant flexibility which can result in a 20% increase in productivity³. However, overcoming the barriers to investment and implementation can be a challenging prospect in addition to the daily demands of a manufacturing facility.  Businesses want good technical support from their suppliers throughout the process from knowledgeable and responsive staff.

For smaller businesses the dilemma can be identifying the optimum time to invest and accurately estimating the period to achieve full return on investment (ROI).  The Government is maintaining the Annual Investment Allowance (AIA) for 2016 at £200,000 which although unlikely to be a sufficient incentive to make a business ‘take the plunge’ it may be enough to make the first years’ tax bill less painful⁴!  What is clear is that businesses, irrespective of size, are looking to the government for financial support in the form of grants and loans.

The new Prime Minister, Theresa May, is promoting a ‘Modern Industrial Strategy’ for Britain with a focus on research and development and she has committed the Government to significant investment.  In addition the Government will launch an “Industrial Strategy Challenge Fund” to back priority technologies such as robotics and biotechnology⁵.  However, many UK businesses believe that the Government should do more to help existing businesses improve their competitiveness in the global arena through Automation.

Is your business automated? If so, how did you find the implementation process?  If not, what are your plans for automation?  We’d love to hear your thoughts so give us a call on 01865 883508 or e mail us at sales@prestoeng.co.uk.

For more information about Presto Engineering please visit our website here and if you would like to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk

References 

 ¹Barclays Corporate, 2015, Future-proofing UK manufacturing. [pdf] Available at: https://www.barclayscorporate.com/content/dam/corppublic/corporate/Documents/research/automation-report.pdf [Accessed 21 December 2016].

²Office for National Statistics (ONS), 2015. Labour Productivity: Q4 2014. [online] Available at: https://www.ons.gov.uk/employmentandlabourmarket/peopleinwork/labourproductivity/bulletins/labourproductivity/2015-04-01 [Accessed 21 December 2016].

³The Manufacturer, 2016, Annual Manufacturing Report 2016. [online] Available at: http://www.themanufacturer.com/reports-whitepapers/annual-manufacturing-report-2016/ [Accessed 21 December 2016].

⁴HM Revenue & Customs, 2015, Annual Investment Allowance: permanent increase to £200,000. [online] Available at: https://www.gov.uk/government/publications/annual-investment-allowance-permanent-increase-to-200000/annual-investment-allowance-permanent-increase-to-200000 [Accessed 21 December 2016]

⁵Prime Minister’s Office, 21 November 2016, PM Announces major researchboost to make Britain the go-to place for innovators and investors. [online] Available at: https://www.gov.uk/government/news/pm-announces-a-2-billion-investment-in-research-and-development [Accessed 21 December 2016].

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So what led us to this conclusion?

To put our idea into context it’s useful to look at some background information starting with data comparing global manufacturing output in 2014 in the top 10 countries.

• Chinese manufacturing output was the highest in the world for the first time at $1.9 trillion.
• The USA were literally ’pipped at the post’ by China at $1.8 trillion having held the number 1 spot from 1970 to 2013.
• Japan took the number 3 spot with $1 trillion and the UK came in 9^th with $247 billion, beaten by the other major European economies of Germany in 4^th, France in 7^th and Italy in 8^th. To complete the top ten South Korea was 5^th, India 6^th and Taiwan 10^th1.

With escalating labour costs in China and increased automation, China is no longer the low cost manufacturing option it was.

But how did it become such a powerhouse of productivity for the last 20 years?

A combination of clever policy, hard work, luck and timing all played their part.  For example, in the 1980’s Margaret Thatcher and Ronald Reagan believed that western economies would move away from manufacturing towards service economies and also gave preferential treatment to the financial industry on Wall Street and in the City of London².   This coincided with China opening up and ‘plugging in’ to the global economy and the rest is history!

Although some particularly labour intensive functions or businesses are chasing lower wages in locations such as Vietnam, Bangladesh, Myanmar and the Philippines an increasing number of businesses see this as the right time to reshore.

Here are some of the reasons why:-

• Declining wage gaps – Chinese wage increases average 12% per annum since 2001
• Technology, for example 3D printing and Robotics³
• Quality
• Security of Supply Chains
• Increasing transport costs
• The ability to rapidly respond to changing market requirements
• Cost of managing overseas operations
• Geopolitical Unrest⁴

As a UK manufacturer producing high quality visible machined parts at a fair price we know we can’t compete if a potential customer is comparing our price to that of a Chinese supplier.  However, it is rather like comparing apples and pears.  Here at Presto, as with other UK manufacturers, we only use European raw material, test everything we receive and have minimal, if any, scrap.  In contrast we are aware that Chinese suppliers are likely to use low quality and untested raw material.  These factors together with lower quality standards contribute to the high scrap rates many customers experience when sourcing components from China.

So let’s be positive as manufacturers and consider the lower value of Sterling an opportunity to lure manufacturing back to the UK.

As always we would love to hear your thoughts on the subject:-

Do you think we can use the current business climate to encourage businesses to reshore?

Have you any experience of reshoring?

Do give us a call on 01865 883508 or e mail us at sales@prestoeng.co.uk.

For more information about Presto Engineering please visit our website here and if you would like to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

References

¹Chris Rhodes, 2016, International Comparisons of Manufacturing. [pdf] available at  http://researchbriefings.parliament.uk/ResearchBriefing/Summary/SN05809#fullreport  [Accessed 6 October 2016]

²Paul Denlinger, 2016, How did China become the manufacturing hub of the world? [online] available at https://www.quora.com/How-did-China-become-the-manufacturing-hub-of-the-world-What-are-some-of-the-things-that-other-developing-countries-can-learn-from-China-to-improve-manufacturing  [Accessed 6 October 2016]

³Sarah O’Connor, 2016, Robots may cut off the path to prosperity in the developing world, FT.com [online] available at https://www.ft.com/content/5d0b1206-36f2-11e6-a780-b48ed7b6126f [Accessed 6 October 2016]

⁴PWC, 2014, Reshoring – a new direction for the UK economy? [pdf] Available at http://www.pwc.co.uk/services/economics-policy/insights/uk-economic-outlook/reshoring-a-new-direction-for-the-uk-economy-ukeo-march14.html [Accessed 6 October 2016]

Useful Websites

ReshoringUK – http://www.reshoringuk.co.uk/

Reshoring Initiative – USA – http://www.reshorenow.org/

The post Reshoring manufacturing to the UK first appeared on Presto Engineering.

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The Lowdown on Additive Manufacturing/3D Printing – Additive Manufacturing/3D Printing has been monopolising the manufacturing media for several years now but what is it all about and is it relevant to all sectors?  Here we will attempt to de-mystify the process, highlight some of the advantages and disadvantages, and point you in the direction of further reading.

Additive Manufacturing is a process by which digital 3D design data is used to build up a component by depositing material in thin layers one by one.  This technology can be used to produce complex shapes which cannot be achieved when using traditional casting or machining methods.  It can be used for low to medium production volumes in a range of materials and little fixed tooling or manual intervention is required beyond the initial product design¹.

Initially used in the automotive and aerospace industries to build prototypes it has spread across sectors and the technology’s potential appears to be almost limitless².

Let’s start by looking at some of the advantages/benefits of the process:-

Eliminates the need for tool production – In terms of time, cost and labour in the product development process, the production of tooling is at the top!  Additive manufacturing can eliminate the need for tool production and the associated cost savings can be significant.

Customisation – The process allows for mass customisation and there are few constraints.  Individual customers’ requirements can be catered for within the same build at no additional cost.

Reduction in Lead Times – Prototypes can be created immediately after completing the part’s stereo lithography (STL) file.  This can save weeks or months of waiting for an externally sourced prototype to arrive.

Complexity – Additive Manufacturing enables levels of complexity that could not be produced physically using traditional methods.  This is making a significant impact on industrial applications as lighter and stronger components can be produced.

Flexible Manufacturing – Manufacturers can operate on a ‘made to order’ principle rather than holding large volumes of standardised products in stock.  This can be particularly beneficial to suppliers that are obligated to hold substantial spare parts inventory.

Sustainable – Additive Manufacturing is proving to be energy efficient utilising up to 90% of standard materials, thereby creating less waste.²

There are also some disadvantages/shortcomings of the process:-

Volume – At this stage 3D printing cannot compete with the speed of traditional manufacturing.  In addition traditional manufacturing is significantly cheaper than producing large quantities based on 3D print technology.  However, the world’s first additive manufacturing (3D printing) machine that can make plastic parts as fast and as cheaply as traditional manufacturing is to be developed by the University of Sheffield Advanced Manufacturing Research Centre (AMRC) with Boeing Design and Prototyping Group.  The machine is being built for the University of Sheffield’s Centre for Advanced Additive Manufacturing (AdAM)³.

Product Liability – Various product liability issues remain unresolved.  For example if anyone can become a manufacturer who is liable if something goes wrong?

Intellectual Property (IP) – How will manufacturers protect their IP?  If the ‘value’ of a product is in a digital file will manufacturers insert copy protections and assign licensing rights to protect their IP⁴.  What happens if a file falls into the wrong hands?

Product Liability – Product liability regulations refer to the manufacturer as the entity liable for damages arising through the usage of products.  How can this be enforced in additive manufacturing?  The Market for 3D printed products and services is predicted to reach $21bn worldwide by 2020 and the law is lagging behind on such issues⁵.

Loss of Traditional Skills – What will happen to skilled Machinists here in the UK?  Are we at risk of wiping out a workforce?

As always we would love to hear your thoughts on the subject:-

Are you using Additive Manufacturing and if so how has it changed your business?

Are you planning to introduce it?

Are you concerned about any particular aspects of the process?

Do give us a call on 01865 883508 or e mail us at sales@prestoeng.co.uk.

For more information about Presto Engineering please visit our website here and if you would like to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

References

¹The University of Nottingham Faculty of Engineering, 2016.  Additive Manufacturing and 3D Printing Research Group [online] Available at: https://www.nottingham.ac.uk/research/groups/3dprg/index.aspx  [Accessed 9 August 2016]

²Global Manufacturing, 2015.  Industry Analysis: The Pros and Cons of 3D Printing [online] Available at http://www.manufacturingglobal.com/technology/408/INDUSTRY-ANALYSIS:-The-pros-and-cons-of-3d-printing [Accessed 9 August 2016]

³University of Sheffield Advanced Manufacturing Research Centre, 2015.  3D Printing goes High Speed and High Volume [online] Available at http://www.amrc.co.uk/news/3d-printing-goes-high-speed-and-high-volume/  [Accessed 9 August 2016]

⁴DLA Piper, 2015.  Technology’s Legal Edge: Top 3 Legal Issues of 3D Printing [online[ Available at http://blogs.dlapiper.com/iptitaly/?p=57233 [Accessed 9 August 2016]

⁵The Financial Times, 2014.  Regulatory concerns hold back 3D printing on safety [online] Available at https://www.ft.com/content/bfab071c-6abc-11e4-a038-00144feabdc0 [Accessed 9 August 2016]

Further Reading

https://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/benefits-commercial-value/

http://www.raeng.org.uk/publications/reports/additive-manufacturing

The post The Lowdown on Additive Manufacturing/3D Printing first appeared on Presto Engineering.

The post The Lowdown on Additive Manufacturing/3D Printing appeared first on Presto Engineering.

Whether you voted ‘in’ or ‘out’ of the EU, following months of speculation Brexit is reality.  The resulting turbulence in the financial markets is beginning to settle and here at Presto we are asking ourselves what Brexit means for UK Manufacturing?

This situation is new to us yet here we are without leadership from our Government yet many of us have businesses to run, customers to satisfy and employees to pay.

The UK is currently the 11^th largest manufacturing nation in the world and directly employs 2.6m people¹ and manufacturing related product sales reached £360.60bn in 2015.²  On that basis it is hardly surprising that EEF, the manufacturers’ organisation, told the government immediately after Brexit that work to ‘shore up’ confidence and secure our industrial future was a priority!³  From the myriad of statements made by industry leaders across the media one thing is clear; a desire for stability.  However, in the Financial Stability Report Press Conference on 5^th July 2016 Mark Carney, Governor of the Bank of England stated that the UK economy has entered “a period of uncertainty and significant economic adjustment.” ⁴

In the wake of Brexit we have been particularly interested to see how the decision may impact the following:-

• Export of manufactured goods
• Foreign Direct Investment (FDI) in the UK
• Skills in the manufacturing sector

Export of Manufactured Goods

Over 50% of UK exports go to the EU and it is difficult to know how this will be impacted.  Whether the UK is in or out of the EU, European standards must be adhered to and a new UK-EU trade deal will be negotiated in due course.⁵   Article 50 of The Lisbon Treaty⁶ sets a two-year window to negotiate a new legal basis for Britain’s trade relationship with the EU although there is potential to extend this period.  This will be an extremely complex process and the question is will the EU try to enforce tariffs and quotas on, for example, the import of cars?  The UK could choose to do the same on a ‘tit for tat’ basis which would result in the consumer losing out on both sides of the channel.

Foreign Direct Investment in the UK

The pound hitting a 31 year low against the US Dollar has been splashed across the media.  There is no doubt that a transatlantic holiday will be more expensive but “a drop in the value of sterling may make the UK a magnet for trade”.  No one knows for sure but the hope is that global markets will be keen to do deals with the UK⁷ but we have already seen foreign investors such as Siemens take a cautious approach.  The company confirmed that while it would continue with plans for a new £310m manufacturing plant in Hull, as a result of Brexit proposals to expand the site were likely to “stall” until issues relating to the UK’s tariffs and trade with the EU have been resolved.⁸

In 2014 the UK attracted more Foreign Direct Investment (FDI) than any other EU country.  However, it is understood that many investors consider the UK’s access to the EU an integral part of their decision.⁵   It will be interesting to see how potential investors react to an ‘independent’ UK and whether the level of FDI fluctuates over the coming months.

Skills in the Manufacturing Sector

British industry continues to suffer from a skills shortage and the end of free movement could exacerbate this problem.  The car industry, as an example, has 30,000 vacancies and needs to be able to recruit skilled workers from Europe.⁹  As of 29th June UK car manufacturing output was up 10% on 2015 and the Society of Motor Manufacturers and Traders (SMMT) reported that revenues in the industry for 2015 were £71billion, a significant contribution to the UK economy.¹⁰  In addition FDI could be impacted as potential investors require assurance that if they invest in UK manufacturing there are sufficient skilled and unskilled staff available for their facilities.

We are living in changing times and there is no doubt that whether you voted ‘in’ or ‘out’ it is in all our interests to make this work.  With change comes opportunity!

What do you think?  How do you think Brexit will impact your business?  We’d love to hear your thoughts so give us a call on 01865 883508 or e mail us at sales@prestoeng.co.uk.

For more information about Presto Engineering please visit our website here and if you would like to discuss a project with us please call us on 01865 883508 or e mail Julian at sales@prestoeng.co.uk.

References 

¹ The Manufacturer, 2015.  UK Manufacturing Statistics [online] Available at http://www.themanufacturer.com/uk-manufacturing-statistics/ [Accessed 6 July 2016]

²Office for National Statistics, 7 July 2016.  Manufacturing and Production Industry [online] https://www.ons.gov.uk/businessindustryandtrade/manufacturingandproductionindustry [Accessed 7 July 2016]

³EEF – The Manufacturers’ Organisation, 27 June 2016. Manufacturers to tell Government: avoid economic limbo and move quickly to secure Britain’s industrial future [online] Available at https://www.eef.org.uk/about-eef/media-news-and-insights/media-releases/2016/jun/manufacturers-to-tell-government-avoid-economic-limbo-and-move-quickly-to-secure-britains [Accessed 7 July 2016]

⁴Bank of England, 5 July 2016. Financial Stability Report Press Conference [online] Available at    http://www.bankofengland.co.uk/publications/Documents/fsr/2016/fsrspnote050716.pdf [Accessed 7 July 2016]

⁵DLA Piper Manufacturing Matters (UK), February 2016. Brexit: Key questions for the UK’s manufacturing industry [online] Available at https://www.dlapiper.com/en/us/insights/publications/2016/02/manufacturing-matters-february-2016/brexit-implications-for-manufacturers/ [Accessed 7 July 2016]

⁶The Lisbon Treaty, 1 December 2009.  Article 50 [online] Available at http://www.lisbon-treaty.org/wcm/the-lisbon-treaty/treaty-on-European-union-and-comments/title-6-final-provisions/137-article-50.html [Accessed 7 July 2016]

⁷KPMG, 24 June 2016.  What does Brexit mean for the manufacturing industry? [online] Available at https://home.kpmg.com/uk/en/home/media/press-releases/2016/06/what-does-brexit-mean-for-the-manufacturing-industry.html [Accessed 7 July 2016]

⁸The Guardian, 28 June 2016.  Siemens freezes new UK wind power investment following Brexit vote [online] Available at https://www.theguardian.com/environment/2016/jun/28/siemens-freezes-new-uk-wind-power-investment-following-brexit-vote [Accessed 7 July 2016]

⁹The Telegraph, 28 June 2016.  Made in Brexited Britain – how the referendum will impact manufacturing [online] Available at http://www.telegraph.co.uk/business/2016/06/28/made-in-brexited-britain—how-the-referendum-will-impact-manufa/ [Accessed 7 July 2016]

¹⁰Business Reporter, 29 June 2016.  Single market European exports ‘crucial’ say motor industry leaders [online] Available at http://business-reporter.co.uk/2016/06/29/single-market-european-exports-crucial-say-motor-industry-leaders/ Accessed 7 July 2016

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There has been a lot of press about Apprenticeships recently and according to the House of Commons Library Apprenticeship Statistics for England there were 499,900 Apprenticeship starts in 2014/15.  This was 59,500 (14%) more than the previous year and the first increase since 2011/12.¹

In 2014/15 there were 18,000 Engineering Apprenticeship starts in England¹ and The Institution of Engineering Apprentices report that Engineering Apprentices are the most valued across all sectors with 53.6% of UK Engineering professionals having completed apprenticeships.²

Closer to home we have first-hand experience as our Managing Director Julian Lay completed a Mechanical Engineering Apprenticeship.  After spending 7 years at Williams Formula 1 Racing gaining experience and subsequently with a subcontract machining company managing the quotation process, Julian started Presto in 1990.  The business has been very successful and now one of Julian’s sons, James, has joined the business and will take over when Julian decides to step back.  James has completed the second year of his Apprenticeship with Banbury and Bicester College in Oxfordshire and is getting more and more involved in the business.

In undertaking research for this blog posting I found a hundred and one advantages and disadvantages of taking on an apprentice.  I wonder how many relate to real life businesses like ours, a specialist engineering company focussed on providing the highest quality machined components at a fair price.  Here are some of the reasons why we recruit and train apprentices:-

Future Talent – Our aim is to take on a new apprentice every one to two years to ensure that we have a continuous flow of new talent into the business.  The key here is to take time during the selection process to ensure that the fit is right.  Candidates may appear to have the right skills and attitude on first meeting but on further examination it transpires that we are not right for each other.  We have developed a detailed selection process which involves them spending time with us at interview, in the Workshop and socially.  It’s a big investment on both sides and we do as much as we can to make sure we arrive at the right decision for us and the candidate.

Succession Planning – As a small business Julian was delighted when James joined the business and started his apprenticeship.  The business has an established customer base that we will be able to service to the same high standard well into the future.  We hope this will give our existing and potential customers confidence in the longevity of the business.  We are going to be around for a long time!

Challenge the Status Quo – As a business we enjoy being challenged whether it is by a complex project or by an apprentice who suggests a different way of working.  We are receptive to new ideas and actively encourage discussion and involvement in projects.  On College days apprentices also learn from their peers working in a range of industries and it’s interesting for them (and us) to learn best practice from each.

Return on Investment – We believe that the more we invest in developing our apprentices in and out of the Workshop the higher the return for all of us.  In the early years our investment of time, knowledge and support is high but as they move through their apprenticeship they become more valuable to the business and we recoup our investment.  Our goal is to develop a skilled and valuable member of our team.

Create Loyalty – We hope that by spending time selecting the right candidates, investing in their ongoing training and development and giving them valuable experience here at Presto they will want to stay with us as part of a skilled and growing team.

If you would like to talk to us about any aspect of our Apprenticeship Scheme please give us a call on 01865 883508 or e mail us at sales@prestoeng.co.uk

If you would like to find out more about Presto and what we can do for you please visit our website

You can find further information about apprenticeships on the government website here

 References:

¹ Jeanne Delabarre, 2015.  Apprenticeship Statistics: England (1996-2015) [pdf] Available at http://researchbriefings.parliament.uk/ResearchBriefing/Summary/SN06113#fullreport [Accessed 8 June 2016]

² Institution of Mechanical Engineers, 2016. More Support Required for Engineering Apprenticeships [online] Available at:  https://www.imeche.org/news/news-article/more-support-required-for-engineering-apprenticeships [Accessed 8 June 2016]

The post Why do we recruit and train Apprentices at Presto? first appeared on Presto Engineering.

The post Why do we recruit and train Apprentices at Presto? appeared first on Presto Engineering.