CNC Machinery Solutions, the exclusive distributor of Doosan machine tools in the UK and Ireland, has supplied Birmingham-based Burcas Ltd., a privately owned specialist engineering subcontractor, with a new large-capacity vertical machining centre.

The machine, a Doosan Mynx 9500/50 with a Doosan-Fanuc control, was installed at the company’s 32,000sq. ft. facility in October 2020 and is being used, primarily at this moment in time, to machine specialist tooling, prototypes and a range of high-precision components for the Nuclear Sector- a manufacturing sector which, owing to its ‘essential’ status, has been largely unaffected by the lockdown and its restrictions.

When not being used to machine parts destined for the nuclear sector the Mynx 9500/50 has also been used, to a lesser extent, to machine high-precision tungsten carbide and High-Speed Steel (HSS) Sheeter and Slitter knives and blades for Burcas’ domestic and internationally-based paper and packaging customers.

The Nuclear Sector – the catalyst

The nuclear sector has always been important to Burcas and, over the last 10 months (since the COVID-19 outbreak), has become even more so owing to a decline in the company’s other major business areas i.e. aerospace, oil and gas etc., caused, in large part, by the impact and effects of the pandemic.

In fact it was the increase in demand for Burcas’ high-quality machining services from customers in the nuclear sector that was the catalyst behind the new Doosan machine tool investment.

Says Mike Burrows, Burcas’ owner and managing director:

“To capitalise on the growing business opportunities in the nuclear sector we, at the beginning of the year, audited our existing machining capacity and capabilities.

“The results of the audit combined with our knowledge of the sector (i.e. the type of components and parts required by our customers, the machinability of the materials being used for these components etc.), highlighted a need for us to strengthen our milling capabilities as a matter of some urgency.

“As a consequence we specced out the type of machine we knew we required in terms of its size and capacity, spindle configuration and speed, torque rating etc., and began researching the market for the ideal machine.

“Although the new machine tool purchase was driven (almost entirely) by an increase in demand from customers in the nuclear sector we never lost sight that it would also become a major machining asset for our future aerospace and oil and gas business – when both returned to something resembling normality.”

To identify the most appropriate and effective machine tool Burcas canvassed the market assessing both the machine tools and their suppliers against its purchase criteria.

The new machine tool purchase: Burcas’ key criteria

1. To be able to machine a wider range of larger and longer components (than had been previously the case) the company determined that it needed a machining centre with a bigger working envelope.
2. Owing to the materials being machined (i.e. stainless steels, hastelloy, titanium, exotics etc.) and their machinability; the type of machining operations likely to be employed (i.e. heavy-duty roughing, interrupted cutting etc.) in producing the parts, and the accuracies and surface finishes required – it was clear that the new machine had to have a rigid design and construction…a powerful, high-torque spindle…a generous sized tool changer and a highly-effective swarf management system.
3. To help optimise machine tool uptime once the selected machine was installed, Burcas looked closely at the depth and breadth of the various machine tool suppliers’ after-sales service and support operations.

Other key criteria included the machine’s cost and its availability.

Meeting the criteria: The Mynx 9500/50

Having canvassed the market and discussed its requirements with a ‘hit list’ of potential machine tool suppliers, Burcas ultimately decided to invest in the Mynx 9500/50 machine for the following reasons:

a) The Mynx 9500/50 is a large-capacity machine with an impressive working envelope (X-axis 2500mm; Y-axis 950mm and Z-axis 850mm), and a large work table (2500mm x 950mm) that can accommodate parts up to 3,500kg in weight (i.e. maximum table load). The machine’s 16m/min rapid rates on all axes make it extremely productive…enabling it to get down to business fast.

b) The Mynx is a rigidly designed and built box-guideway machine.

It is equipped with a powerful, two-speed gear box driven (22kW/10,000rpm), high-torque (452 Nm) spindle, with a BT50 face and taper configuration that makes it ideal for heavy-duty cutting operations, long machining runs and the efficient and accurate machining of ‘difficult-to-machine’ materials.

c) The machine features a 40-position ATC with a fast (2.5 second) tool change over time for improved productivity and flexibility, and a high efficiency four row screw chip disposal system that delivers improved efficiency and process reliability.

d) The Mynx 9500/50 is supplied and supported by CNC Machinery Solutions who’s pre- and after-sales and service offering is widely recognised as being ‘the best in the business’.

Says Mike Burrows:

“The Mynx 9500/50 is our first Doosan machine and since its installation it hasn’t missed a beat. The machine is versatile and reliable, and its cutting performance is impressive.

“In addition to the machine we have also been impressed with CNC Machinery Solutions. From the outset they adopted a proactive role and, even a tricky installation that necessitated the craning in of the machine through the roof, was professionally managed and executed.”

About Burcas

Burcas, established in 1941, is a company run on sound business principles. It is committed to continuous improvement and, as part of its vision and values, “strives for perfection and 100% customer satisfaction”.

The company has, over many years, built a strong reputation in and across the many markets it serves (both domestic and international) for -: a) the quality and accuracy of its machined products; b) its speed of response and ability to fulfil customers’ lead times and delivery schedules; c) its competitive pricing policies.

Essential to the company’s success and its ability to work across so many industries and sectors has been its progressive attitude to investing in the latest manufacturing and machining technologies.

Says Mike Burrows

“We constantly monitor and evaluate all aspects of our business. If, and when, we identify an area that needs attention or improvement we act decisively.”

In recent years this strategic outlook has seen the company invest in a number of advanced machine tools, optimise its processes and systems and integrate an effective ERP/MRP system across its operations to improve efficiencies and effectiveness.

Burcas is committed to quality and, as well as having ISO 9001 and AS9100 Rev D certification, also holds a number of customer-specific approvals.

Concludes Mike Burrows:

“The new Mynx 9500/50 investment is another example of Burcas’ commitment to continuous improvement and of us striving to be the best we can be.”

The post CNC Machinery Solutions helps make a tough machining decision easy! appeared first on CNC Machinery Solutions.

CNC Machinery Solutions, the exclusive distributor of Doosan machine tools in the UK and Ireland, has recently supplied Birmingham-based Cutting Blue Ltd., the newly-created manufacturing arm of engineering consultancy and training specialist, Cutting Blue Solutions Ltd., with a new Doosan vertical machining centre.

The machine, a large-capacity DNM 6700, was delivered and installed at the company’s 2,000 sq. ft. facility in Saltley in September 2020 where it is being used to machine, in mainly small batch sizes at this moment in time, high-precision and high-value components for a range of customers operating in the motorsport and general engineering sectors – to name but a few.

About Cutting Blue

The creation of Cutting Blue Ltd is the brainchild of owner and managing director, Piotr Parobczy.

Having started his working life, first as a machine tool setter and then as a CAD/CAM programmer, Mr. Parobczy used this knowledge and experience, gained from working in a number of different manufacturing environments, to develop and hone a range of specific engineering consultancy skills.

The acquisition of these skills ultimately enabled him to start, and secure, work as a contractor where (over the years) he was responsible for the design and implementation of innovative and high-value projects for a number of UK- and internationally-based customers.

Following on from this success, and having built up an impressive track record Mr. Parobczy, in 2017, set up Cutting Blue Ltd – an engineering service company providing specialist training and consultancy services to blue-chip and progressive manufacturing companies.

Says Piotr Parobczy:

“Cutting Blue Ltd., began its life as a engineering consultancy.

“However, even back then it was always my ambition and intention to create a manufacturing company – when the time was right.”

That time, as it transpired, was in Spring 2020.

Explains Piotr Parobczy:

“The pandemic outbreak had a detrimental effect on the availability of contract work and this proved to be the catalyst I was waiting for.

“Because the creation of a manufacturing company was a long held ambition of mine I was not starting such an undertaking from scratch. To a large extent much of the spadework and planning had already been done.”

These plans covered all aspects of the business including – the location of the new company…the services it would provide…typical customer profiles etc.

Continues Piotr Parobczy:

“I chose Birmingham because of its central location and because I knew the area well.

“From my background and experience the company would not be a ‘jack of all trades’ operation but instead would offer specialist, high-precision machining (milling) services to customers typically operating in the high-end motorsport, automotive and aerospace sectors.”

To realise its ambitions and objectives Cutting Blue needed access to advanced machine tool technologies – and made the decision, from a reliability perspective and to provide a clear statement of intent, to invest in a new rather than a used machining centre.

The Doosan: CNC Machinery Solutions angle

Cutting Blue approached a number of machine tool manufacturers with its requirements.

Says Piotr Parobczy:

“A number of companies I approached sent in literature etc., but didn’t follow things up.

“I got a different reception and reaction from CNC Machinery Solutions who, from the outset, adopted a more proactive and partnership approach. They took time to understand the business and the type of work that would be undertaken: they worked collaboratively with me to identify the optimum machine tool solution.”

The Doosan DNM 6700

Understanding the type and size of components to be machined…the typical materials to be machined (i.e. aluminium, steel, Stainless, titanium, engineering plastics etc.)…the typical part accuracies and surface finishes that would be required…and the volumes/batch sizes to be machined – resulted in the identification, selection and, ultimate, ordering of a Doosan DNM 6700 – a large-capacity vertical machining centre.

The Fanuc-controlled DNM 6700 installed at Cutting Blue’s facility is a highly-rigid machine that delivers speed, high accuracy and unrivalled process reliability.

It is equipped with a 18.5kW/12,000rpm directly-coupled (high-speed) spindle, a 1500mm x 670mm work table with a 1300kg maximum table load, a 30-position ATC, roller LM guideways (all axes) and thermal error compensation.

The machine was also supplied with a Blum TC50 workpiece touch probe and Blum ZX Speed IR tool setting probe.

Says Piotr Parobczy:

“I was already familiar with Doosan machine tools and knew that they were reliable, represented great value and delivered excellent cutting performance.

“The DNM 6700, with its large work table, provides much needed capacity, capability and flexibility (now and in the future) enabling us to machine large or multiple smaller parts in one set-up.

“Although still early days I am delighted with the DNM 6700 and am already looking at investing in second Doosan machine.”

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CNC Machinery Solutions, the exclusive distributor of Doosan machine tools in the UK and Ireland, has supplied Quick Machining Solutions Ltd., a leading precision subcontract specialist based on the outskirts of the New Forest, with a new vertical machining centre.

The machine, a Doosan DNM 4500, is a compact, high-performance and best-selling 3-axis machining centre that has become a firm favourite amongst precision component manufacturers in the UK and Ireland. The new machining centre was installed at Quick Machining Solutions’ modern, refurbished 7,000sq. ft. facility in September 2020.

Investment rationale

Investing in a new machine tool during the pandemic, at a time when many manufacturers were (and still are to some extent) ’battening down the hatches’ has helped Quick Machining Solutions meet a growing demand for its high-quality machining capacity and capabilities.

Explains Wayne Harris, owner and managing director:

“A number of component manufacturers closed down their operations and/or furloughed a significant number of their staff in response to the pandemic outbreak.

“We felt that even in these uncertain times, we had an obligation to our customers to remain open whilst ensuring we did everything to keep our staff safe.  We also used any spare time for training, maintenance and other improvements within the business.

“As a consequence of ‘keeping our doors open’ we were able to pick up new business from a number of customers who were having difficulty sourcing their machined parts in the necessary timescale.

“This increase in demand, in addition to continually improving our machining (milling) capabilities, was the main catalyst behind the DNM 4500 investment.”

Machine tool requirement​

To ensure that the new machining centre would meet it’s immediate and future machining requirements, the company drew up a checklist and investigated the market.

Says Wayne Harris:

“We needed a high-performance 3-axis machine with a compact footprint and a good-sized working envelope (to handle a wide range of different-sized parts).

“We also needed a machine with a Heidenhain 640 control (our preferred VMC platform) to be able integrate with our existing machines and program database.

“We had looked at acquiring a Doosan DNM 4500 at the start of the year but had postponed the decision…temporarily as it transpired.

“However, the increase in demand and the need for a swift delivery (caused in part by the impact and effects of the pandemic)… combined with a great purchase price we were able to negotiate with Mills for a new DNM 4500, meant that the investment was given the go-ahead.”

Since being installed the DNM 4500 has been used to machine a range of components for customers operating in the motorsport, film, leisure and industrial sensor sectors…to name but a few.

These components, machined in small to medium batch sizes and from a variety of materials that include aluminium, stainless steels, titanium and engineering plastics, often exhibit tight tolerances (i.e. down to a few microns in some instances) and superior surface finishes (Ra 0.1µm).

The DNM 4500

The DNM 4500 machine supplied to Quick Machining Solutions is equipped with a powerful, direct-drive 12,000rpm spindle, a large 1000mm x 450mm work table, a 30-position ATC and the latest Heidenhain (TNC 640) control.

The machine also features roller LM guideways and thermal error compensation to ensure high accuracies and repeatability’s over long machining runs.

Says Wayne Harris:

“The machine is versatile and is a great all-round performer. It was available at an extremely attractive price.

“We ordered the machine in September and in the same month it was delivered, installed and was cutting metal.”

Background: Quick Machining Solutions

Quick Machining Solutions was established in 2010 and, over the last ten years, has achieved significant growth and success.

The company today employs eight members of staff, has substantially increased its turnover (since the early days) and, to win new business and secure (and elevate) its position within customers’ supply chains, has achieved ISO 9001: 2015 accreditation.

The company’s commitment to continuous improvement is further reflected in its strategic and prudent investment in new and advanced machine tools and ancillary technologies as evidenced by its first Doosan machine tool investment made 18 months ago.

The first Doosan machine

In November 2018 Quick Machining Solutions invested in a new Doosan Lynx 2100LMA multi-axis turning centre. The lathe was supplied (by Mills) with an integrated servo-driven bar-feeder.

Comments Wayne Harris:

“To maintain our competitive edge we made the strategic decision (back in 2018) to invest in a flexible, high-performance multi-tasking turning centre.

“We were looking for a lathe that was fast, powerful and accurate. And we were specifically keen on acquiring a machine that was equipped with driven tooling to help us reduce set up and part cycle times. We also wanted the lathe to be supplied with a bar feeder to help us improve productivity and facilitate ‘lights-out’ and unattended operations.”

Before any purchase decision was made Quick Machining Solutions did its homework and researched the market.

The results of the research revealed that Doosan lathes were extremely popular amongst component manufacturers and that, for small parts production, the Lynx range came highly recommended.

On the basis of its research findings, that also included visiting an existing Mills customer and Lynx lathe user, Quick Machining Solutions placed its order for a Lynx 2100LMA.

Comments Wayne Harris:

“The Lynx lathe is a real workhorse and, since its installation, hasn’t missed a beat. The performance and reliability of the Lynx lathe, and the ease of doing business with Mills, were major factors in us deciding to invest in the DNM 4500.”

Investing in new technology as well as its people, plant and manufacturing processes and systems is definitely the ‘direction of travel’ for the company in the future. Other recent and planned investments to improve its performance include:

1. the recent purchase/integration of a MRP system to help improve productivity and operational efficiencies,​
2. an investment in a new CMM (Coordinate Measuring Machine) to improve its inspection capabilities,
3. the roll out of an ambitious and innovative plan to generate its own solar energy to power its plant,
4. the continuation of its popular and successful in-house apprenticeship programme to meet its skills requirement.

Continues Wayne Harris:

“We are always looking to improve and innovate.

“We have built a solid reputation in the market based on the quality of our machined components… the speed of response and the fast turnaround times we can achieve for customers…and our competitive prices.

“In a relatively short space of time, we have become a ‘go-to’ precision component manufacturer for customers operating in number of industries and sectors.

“Our investments in Doosan machine tool technologies have been more than instrumental in helping us get to where we are.”

The post Quick thinking! appeared first on CNC Machinery Solutions.

The advanced 10“ chuck box-guideway multi-tasking lathe, a firm favourite amongst UK and Irish component manufacturers ever since its introduction in 2018, features a powerful built-in spindle (22kW/4000rpm), a Y-axis (+/-52.5mm), a sub-spindle (15kW/6000rpm) and driven tooling capabilities (7.5kW/5000rpm).

In addition to its high specification, the model supplied to IMR also featured a number of ancillary technology additions to increase its productivity and efficiency. These included:

• a Hydrafeed servo-driven bar feeder
• a Filtermist oil/mist extraction unit
• a Renishaw optical workpiece inspection probe
• a LNS swarf conveyor system
• a FSE filtration system
• Hainbuch collet chucks

The lathe was also supplied with an auto door and a robot interface (to facilitate automated workpiece loading/unloading in the future).

The Puma 2600SY II was installed at IMR’s 35,000 sq. ft. Technology Centre in late August 2020.

About IMR

Irish Manufacturing Research (IMR) is a leading manufacturing Research and Technology Organisation with labs and industrial pilot lines in Dublin and Mullingar, Ireland.  IMR works with leading global and indigenous brands to demystify and derisk new and emerging technologies, and to deliver high-impact collaborative research to enable global leadership in advanced manufacturing.

IMR has over 60 researchers with 100’s years of combined industry expertise working in areas such as 3D printing, Data Analytics, Knowledge Management, Sustainable Manufacturing, Advanced Robotics and the Industrial Internet of Things.

IMR activities span national and European research collaborations, prototyping services, training, and Industry networks.

 The CNC Machinery Solutions angle

Says Chris Judge, IMR’s Machining Applications Specialist:

“Our main R & D spheres of influence comprise the following (four) ‘thematic pillars” – digitisation, automation and advanced control, design for manufacturing and sustainable manufacturing.

“To deliver innovative and credible solutions we (too) need access to the latest and most advanced technologies. You simply cannot say that you create state-of-the art solutions if the technology you use and that is at your disposal is anything but.

“As such we rely on a number of hand-picked partners to work with us in delivering technology solutions to industry. From a machine tool supplier perspective the partnership we have recently entered into with CNC Machinery Solutions makes perfect sense.”

CNC Machinery Solutions is highly regarded in Ireland, resonates with Irish manufacturers and, year-on-year, supplies a significant number of advanced Doosan machine tools and automation solutions to a growing number of OEMs, Tier One suppliers, and precision subcontractors.

In addition to its strong and resilient machine tool sales infrastructure, Mills has invested heavily in recent years in developing an Irish-based service and support operation (i.e. CNC training, applications and technical support, machine tool servicing and parts, finance etc.), and this investment into research in Ireland, further demonstrates the company’s commitment to the Irish market.

Continues Chris Judge:

“Some months ago, we identified that we needed to develop our in-house CNC turning capacity and capabilities at our Technology Centre in Mullingar.

“Through talking to manufacturers about research opportunities and the different technologies available, and the relative skills and strengths of individual technology suppliers, it became clear that CNC Machinery Solutions (and the Doosan machine tools it supplies and supports) was the preferred choice for many.

“Through discussions with the Mills team and their Irish Business manager Declan Boyle about our needs and requirements, we identified the ideal turning centre solution – a new Puma 2600SY II multi-tasking lathe.

“To help ‘future proof’ the investment and increase the scope and scale of future R & D projects, the Puma lathe we ordered was supplied with a number of additional ‘extras’ that included a bar feeder, workpiece probing, oil/mist extraction and high-performance collet chucks etc.

”I would like to take this opportunity of thanking Mills and the different technology suppliers involved for their support: it is very much appreciated.”

Although the Puma was only installed a few weeks ago it has already been involved in a number of customer-led projects.

One of these has involved exploiting the lathe’s multi-tasking capabilities – using the Puma lathe’s Y-axis, mill-drill and capabilities to significantly reduce the number of machining operations, reduce cycle times and conduct in process inspection to improve part quality.

The project has demonstrated that the Puma lathe’s onboard technologies (including its thermal compensation capabilities) can significantly reduce part processing times – from five down to just one operation – and increase part accuracies.

Concludes Chris Judge:

“Projects are lining up for the Puma and, because the lathe is ‘automation ready’ we expect, in the not-too-distant-future, to integrate it with a CNC Machinery Solutions industrial or collaborative robot – thereby increasing its use and appeal with Irish manufacturers.”

The post The collaborative imperative! appeared first on CNC Machinery Solutions.

CNC Machinery Solutions, the exclusive distributor of Doosan machines in the UK and Ireland, has supplied 17D Ltd., a leading family-owned miniature railway manufacturing specialist, based in Matlock, Derbyshire, with a new Doosan vertical machining centre.

The machine – a compact, high-performance DNM 4500 – was installed at 17D’s (2,500sq. ft.) facility in July 2020, and is being used to machine a range of precision components, that include live steam locomotive parts (valve gears, cylinders etc.), chassis, axles, bogies, couplings, buffers, wheels etc., made from a diverse range of materials that include aluminium, cast iron, carbon steel etc.

17D, established in 2010, manufactures a range of scaled working models of locomotives, carriages and wagons for three miniature railway gauge systems: 5”, 7.1/4” and 10.1/4”. (The company’s locomotives for the 5” gauge are a scale of one-twelfth, at around six feet long, rising to approximately 12 feet for the 10.1/4” gauge).

In addition to designing and manufacturing miniature locomotives and associated rolling stock, the company is focused, and devotes significant time and resources, on producing and supplying high-quality, cost-competitive and quick turnaround parts and spares for a myriad of UK and internationally-based customers that include hobbyists and private collectors through to clubs and commercial organisations.

The company has a strong reputation in the markets it serves and is highly regarded. And to maintain its market leading position and competitive edge, 17D invests regularly in its plant, equipment, processes and systems.

The company’s commitment to continuous improvement combined with a dramatic and sudden upsurge in demand for its machined parts were the driving forces behind 17D’s new DNM 4500 machine tool investment.

Explains partner, Tristan Dengate:

“Business had been growing incrementally but the onset of the Covid-19 pandemic resulted in a sharp and dramatic increase in demand from hobbyists who, having been furloughed as part of the lockdown, had time on their hands.

“This increase in demand was putting a strain on our existing machine tools so, to ensure we could meet customer expectations, we made the decision to strengthen our capabilities and invest.”

The DNM 4500 rationale

 17D has a variety of CNC and manual machines at its disposal and had, in November 2019, strengthened its turning operations by investing in a used 6” chuck/51mm bar diameter Doosan Lynx 220LM lathe equipped with a C-axis and driven tools.

Says Tristan Dengate:

“The arrival of the Lynx lathe had an immediate and positive effect helping us to reduce part cycle times, eliminate production bottlenecks and improve lead time fulfilment.

“Although the machine is a few years old it still delivers exceptional performance and hasn’t missed a beat since installation.”

The machine’s arrival and subsequent performance also ‘converted’ 17D into becoming Doosan machine tool advocates.

Continues Tristan Dengate:

“The increase in demand for machined parts, which started at the onset of the pandemic in April, was putting pressure on our milling resources. We needed additional milling capacity and capabilities and we needed them fast!

“Our experience with the Lynx 220LM helped narrow down our choice: put simply we wanted a Doosan.”

17D drew up a list of key requirements, investigated the market and approached CNC Machinery Solutions.

“We needed a versatile, high-performance machine: one that could deliver high (and accurate) metal removal rates combined with an ability to machine intricate part details and features, and achieve super-fine surface finishes”, says Tristan Dengate.

To help reduce part cycle times the machine also needed to be able to cope with high speeds and feeds, and aggressive depths of cut.

The company had narrowed down its choice to a DNM 4500 machining centre and, with funding in place via a EU Grant, placed the machine order with CNC Machinery Solutions.

Says Tristan Dengate:

“We ordered the machine on a Monday and it was delivered and installed by the end of that week.”

The Doosan DNM 4500

The DNM 4500 is a high-speed, highly-rigid and versatile 3-axis vertical machining centre ideal for a range of applications. Standard features (and major selling points) include a large working envelope (800mm x 450mm x 510mm), a direct-coupled spindle (18.5kW/8,000rpm), roller LM guideways and an on-board thermal error compensation system.

The machine boasts fast rapid rates (36/26/30m/min), a large work table (1000mm x 450mm with 600kg maximum table load), and a 30-position ATC.

The machine supplied to 17D was equipped with the Fanuc i control but can also be specified with either a Siemens 828D or Heidenhain TNC 620 control.

Concludes Tristan Dengate:

“The DNM 4500 is a great addition to our operation.

“We are confident that the machine will be more than instrumental in helping us further grow our business – not just with our miniature railway customers but also with customers (from other sectors) looking for a proven, high-quality machining subcontract specialist.”

The post Small objects of desire! appeared first on CNC Machinery Solutions.

As rewarding as becoming your own boss can be, starting a business from scratch comes with many risks and challenges. What determines the success or failure of a startup is the way these risks are managed.

Some of the biggest challenges can occur in the infancy stages of a business.

After taking the initial plunge – itself a brave move for many (and definitely not for the fainthearted) – a myriad of other issues need to be addressed and managed – often simultaneously.

Many of these issues, if not handled successfully, will stop a business in its tracks: (it’s worthwhile remembering that 90% of business startups fail in the first 12 months).

Conversely, if the issues are tackled head on and are managed strategically, the odds on a business surviving, and growing, increase exponentially. 

This article focuses on Didcot-based, Endeavor Engineering Ltd., – a precision engineering subcontract specialist that, through sound management practices and a commitment to continuous improvement, has navigated its way (and continues to do so) through the difficulties and obstacles that beset many companies.

Endeavor Engineering, created by directors Andy Strong and Martin Bell in 2012, had a vision when they formed the company.

The vision, as relevant today as it was back then, was straightforward and unequivocal, and focused on the company directing and using all its resources ‘to machine high-precision, competitively-priced components and to deliver them on time…every time to customers.’ The aim being to provide customers with high-quality, best-in-class manufacturing solutions accessed from a single and reliable source.

This vision combined with a commitment to…

1. constantly and systematically review and evaluate the market in order to identify business opportunities;
2. invest in new, advanced machine tool and manufacturing technologies;
3. create technical leadership and differentiation through acquiring general and domain-specific business knowledge;
4.  adopt a flexible approach and be willing to adjust (but not constantly adjust) to changing market dynamics.

…have stood the company in good stead over the last eight years.

i) Researching the market – start as you mean to go on.

Endeavor Engineering is located in Didcot, Oxfordshire.

The area has a thriving manufacturing base supporting and supplying the UK motorsport sector and a number of scientific research organisations and facilities.

Says Andy Strong:

“We knew the area well and our research revealed that there was a definite need for high-precision subcontract machining services from companies (potential customers) operating in the area. As long as we had the right technologies and business processes and systems in place, we were confident that we could secure high-value work from them.”

In the first few years Endeavor was successful in securing significant work from a range of companies including F1 and motorsport teams.

Comments Andy Strong:

“Supplying the motorsport sector is demanding.

“Quality and lead-time fulfilment are of paramount importance. High-accuracy components are machined and supplied in small batches – sometimes prototypes and one-offs – and fast turnarounds are the norm.

“If your manufacturing methods and processes are not geared up for this kind of manufacturing – you won’t last long.”

Today, Endeavor still works closely with a number of F1 teams but is not over reliant on the sector.

Continues Andy Strong:

“We have made a conscious decision to have a balanced portfolio of clients from a number of different sectors. This approach makes our business less vulnerable if a downturn occurs in one of the sectors we serve.”

Although the company has less dependancy on the motorsport sector today than in the past, the in-house methods and production procedures developed, and the lessons learned from operating within the industry, have been invaluable. They have been transferable too.

Explains Andy Strong:

“We have diversified our customer base and now machine complex, high-precision parts for customers in the semi-conductor, oil and gas, aerospace and scientific instrumentation sectors.

“These customers, similar to the those in the motorsport sector, demand high accuracies and repeatability’s i.e. close geometric tolerances on parts and machined features, as well as an ability to machine super-fine, mirror-like surface finishes.

“Our impressive track record in the motorsport sector has been instrumental in our ability to win machining contracts from customers in these sectors.”

ii) Investing in new advanced machine tool technologies

From the outset Endeavor has invested in new, advanced Doosan machine tool technologies from CNC Machinery Solutions.

The company now has eight Doosan machines at its disposal (3 x Puma lathes and 5 x DNM-series machining centres).

Says Martin Bell:

“There is a temptation for startup businesses to invest in used (as opposed to new) machine tools. However, the performance of used machines can be inconsistent and unpredictable.

“As a consequence, when we formed the company, we made the strategic decision to invest in new machine tools technologies – and have done so ever since.”

Endeavour selected Doosan machine tools (supplied by CNC Machinery Solutions) as a result of first undertaking an extensive search into the market…investigating not only the type and range of machine tools on offer – but also the credentials and reputation of the different machine tool suppliers.

Continues Martin Bell:

“We did our homework. We spoke to customers. And we attended Trade Shows.

“From our research we found that Doosan machine tools were popular. They had a good reputation in the market and were renowned for their quality, performance, reliability and value.

“We also found that CNC Machinery Solutions was similarly highly-regarded not only for the machine tools they sold but also for the after-sales services and support they provided.

“When we first approached them (Mills) to discuss our machining requirements, they understood what we were trying to achieve and were onboard immediately.”

Endeavor has eight (Fanuc-controlled) Doosan machines in operation at its facility. They include multi-tasking lathes with driven tools and C- and Y-axes capabilities, and machining centres with advanced spindle technologies that deliver fast, high-accuracy volumetric removal rates and super-fine finishes.

The Doosans are being used to machine a range of components made from a diversity of materials – i.e. steel, stainless steel, Duplex, titanium, aluminium, plastics, composites etc., to exacting accuracies and finishes.

Says Martin Bell:

“We have a good relationship with CNC Machinery Solutions based on mutual integrity and trust. In addition to us investing in Doosan machine tools we also use Mills’s independently-operated machine tool finance arm (to help fund our investments) and its CNC Training Academy (to help train our programmers and operators).”

iii) Creating technical leadership and differentiation

Endeavor has built its business and reputation on delivering technical excellence and unrivalled customer service.

Everything from the company’s recruitment through to its ongoing investment in plant and equipment, and systems and processes, is monitored and evaluated. If, and where, any weaknesses are identified – the company acts quickly and decisively to rectify them.

Says Andy Strong:

“Continuous improvement is a journey – not a destination. We are constantly looking to move forward and to be the best we can possibly be.”

iv) Flexibility and a willingness to adjust

 A major tenet underpinning Endeavor’s continuing growth and success is its flexibility and willingness to change course, where and when required.

The decisions to increase the company’s headcount, move into the semi-conductor market and reduce its reliance on the motorsport sector are all cases in point.

Remembers Martin Bell:

“There was a watershed moment when we took control of the business and its future direction.

“We decided that running from pillar to post, working all the hours that God sent, was not sustainable in the long term.

“We made the decision to run the business rather than let the business run us. That decision has paid dividends.”

Endeavor has a rolling Five Year Plan that is flexible, and that is reviewed and updated regularly to ensure its relevancy.

As part of the Plan, the company is hoping to increase its current 4,500 sq. ft. floorspace by acquiring premises adjacent to its existing facility, in the near future.

The new space will be used to improve workflow and enable the company to invest in new technology to boost its manufacturing capabilities still further.

Concludes Andy Strong:

 “We are always striving to improve. Such are the globally competitive markets where we operate that ‘if you’re not moving forwards it’s likely that you’re going backwards. We are a company that’s definitely on the front foot.”!

The post On the front foot! appeared first on CNC Machinery Solutions.

Ayrshire-based NPI Solutions Ltd., has recently invested in two new Doosan vertical machining centres and a new Doosan cobot – all supplied by CNC Machinery Solutions.

The machines – a Doosan DNM 4000 and a DNM 6700 – were installed at the company’s 46,000 square foot facility in the first week of July (2020) and replace two older machining centres that had served the company well but which had seen better days.

The Doosan M1013 cobot, the company’s first investment in a robotic automation system, was delivered and installed in late July.

The decision to invest in new machine tool and automation technologies was made during the height of the pandemic in April.

At a time when many manufacturers may have understandably been ‘battening down the hatches’, NPI chose a different route; one entirely in keeping with the company’s business ethos and approach.

Says Kevin Priestley, NPI’s managing director:

“We are a company that’s committed to continuous improvement and, as such, regularly monitor and review our performance.

“We had become aware (earlier in the year) that two of our older machining centres were creating a ‘pinch point’ in our operations and were affecting our productivity and efficiency.

“We decided that we wanted to replace the two older machines and approached CNC Machinery Solutions to discuss a way forward.”

NPI is no stranger to CNC Machinery Solutions or to the Doosan machine tools it sells and supports.

The company, since 2011, has made a number of strategic investments in Doosan machine tools and, prior to the addition of the two latest machines, had acquired three Doosan lathes and three Doosan machining centres.

Says Kevin Priestley:

“Doosan machines are reliable and represent good value. We like Mills. They know our business and we believe the company’s after-sales service and support is hard to beat.”

The two new DNM machines acquired by NPI are proven performers and are best-selling models.

The DNM 4000 is a compact machining centre equipped with a 18.5kW/12,000rpm direct-drive spindle, a 20-position quick-change ATC and, inline with NPI’s preference, the Fanuc 0iMF control. The machine boasts impressive rapid rates (48m/min) and, like all newer DNM models, features an innovative and efficient grease lubrication system that eliminates the need for an oil skimmer and reduces lubrication costs by up to 60%.

The DNM 4000 is also versatile and delivers excellent cutting performance. It is fast and accurate and, in many respects, is similar to the larger Doosan DNM 6700 machine which is equipped with a 18.5kW/8,000rpm direct-coupled spindle, a larger ATC (30/40position), grease-lubricated LM roller guide ways and thermal error compensation system that ensures high-accuracy over long machining runs.

Explains Kevin Priestley:

“We machine high-precision components – from prototypes and small batch series through to larger volumes – for a growing number of UK and international customers.

“To meet their quality and lead time demands we need access to reliable, high-performance machine tool technologies. The new Doosan machining centres are a case in point.”

The company’s commitment to continuous improvement and willingness to invest in the (its) future was the driving force behind its (first) collaborative robot investment.

Says Kevin Priestley:

“We are always looking to improve and recognise the power and potential of automation.

“In discussions with Mills’ sales and technical consultants we began exploring the benefits we could gain from integrating a cobot with our Doosan DNM 350-5AX (5-axis) machining centre acquired in 2016.”

“The ability to run the machine and cobot unattended was particularly appealing and would help us really take advantage and exploit of the DNM 350-5AX’s one-hit machining capabilities.

“Lights-out operations is a desired state. The cobot investment is a first step in getting there.”

Prior to deciding on the Doosan M1013 cobot, NPI approached other cobot suppliers.

Concludes Kevin Priestley:

“The Doosan cobot was selected for its build quality, and its safety, payload and reach radius characteristics. The fact that it was backed by CNC Machinery Solutions made it an easy decision to make.”

The post Out with the old and in with the new. appeared first on CNC Machinery Solutions.

CNC Machinery Solutions, the exclusive distributor of Doosan machine tools in the UK and Ireland, has recently supplied Baker Engineering Ltd., a leading precision toolmaker and engineering subcontract specialist, based in Derby, with a new, high-performance Doosan DVF 5000 (5-axis) machining centre.

The machine was installed at the company’s new, purpose-built 8,000 square foot facility in April 2020 and is being used to machine a diverse range of high-precision components, as well as specialist tooling, jigs and fixtures for its growing UK and international customer base.

The DVF 5000 is the second Doosan machine tool Baker Engineering has invested in recently; the first being a new DNM 6700 vertical machining centre which was acquired in February 2017.

5-axis machine tool investment: rationale

Baker Engineering is a family-owned business established in 2008 that today employs 15 members of staff.

The company is ISO 9001: 2015 accredited and is committed to continuous improvement making regular investment in the latest machine tool and ancillary manufacturing technologies to maintain its competitiveness and strengthen its preferred partner relationships with its customers.

Baker Engineering has a number of CNC machines at its disposal; these include machining centres with integrated 4th-axis units, lathes with bar feeders, and wire EDM machines.

In addition to offering precision subcontract machining services the company also has specific strengths in manufacturing aerospace component tooling (i.e. jigs and fixtures for ground support maintenance); tooling for the measurement and inspection of railway tracks; and tooling used in the power generation sector).

As a forward-thinking company the decision to invest in the latest 5-axis machining technology was a natural one for Baker Engineering to make and had begun, in earnest, earlier in 2019.

Explains Director, Adrian Baker:

“Multi-axis and multi-tasking machine tools help manufacturers improve their productivity. Because we are a company that’s looking to constantly improve we had done our homework into the technology and could see that an investment in a 5-axis machine tool would deliver significant performance benefits.

“In addition, the investment would send the right signals, externally and internally, that Baker Engineering was focused on the future.”

The key advantages from investing in 5-axis machine tool technology were immediately apparent to management and staff at the company and included:

• the ability to machine complex shapes/parts in a single set-up.
• the added benefit that ‘one-hit’ machining has on reducing the time and costs involved in fixturing.
• the ability to improve/maintain part accuracies owing to a reduction in work handling.

Says Adrian Baker:

“Since the DVF 5000 machine’s installation we have experienced all of these benefits.”

A demonstration of the machine’s capabilities, and its impact on Baker Engineering’s performance, can be seen in the following example.

Component case study

A customer electrical housing-type component was machined, prior to the arrival of the DVF 5000, in five separate machining operations with a cycle time of 2.5 hours. When machined on the DVF 5000 the number of operations was reduced to two, and the cycle time was 0.75 hours.

Comments Adrian Baker:

“The above is typical of the results we have been able to achieve since we invested in the machine”.

CNC Machinery Solutions

Prior to making the 5-axis machine tool investment decision, Baker Engineering did its homework and investigated the market in order to help identify the type of machine that would ‘fit the bill’.

Comments Adrian Baker:

“We had invested in a DNM 6700 vertical machining centre from CNC Machinery Solutions in 2017. We have been pleased with the machine’s performance and reliability, and have been impressed with Mills’ after-sales service and support.

“When considering the 5-axis machine tool investment is was natural that we approached them to discuss our requirements.”

These discussions resulted in the DVF 5000 being recommended.

The DVF 5000

The Doosan DVF 5000, a popular and best-selling 5-axis machine from CNC Machinery Solutions’s impressive machine tool portfolio, is a compact and rigidly-built machine that delivers excellent cutting performance and unrivalled machining flexibility.

The machine offers full simultaneous 5-axis machining capability as well as 3 + 2 and 4 + 1 operation. (Baker Engineering is predominantly using the machine for 3 + 2 and 5-face machining).

The DVF 5000 features a powerful, direct-drive spindle (up to 18.5kW/12,000rpm), a generous-sized tool changer (up to 120 position), linear guides, and a 500mm x 450mm work table with 400kg table load.

The machine is fast boasting 40m/min rapids and was supplied to Baker Engineering with a 60-position ATC, integrated tool measurement and the latest Fanuc 0iMF control.

Since installation – added benefits

The DVF 5000 has been fully operational at Baker Engineering’s facility since the end of April 2020 and has been in constant use since then.

As well as it helping the company increase its productivity and efficiency the machine has also helped Baker Engineering win new machining work.

Explains Adrian Baker

“News travels fast.

“On hearing that we had invested in Doosan 5-axis machine tool technology – a new customer made contact with us asking us to quote on a job. We have successfully turned the enquiry into an order.

“Our decision to invest in the Doosan DVF 5000 has been vindicated. The machine has significantly strengthened our machining capacity and capabilities. It is fast, accurate and reliable, and represents great value.”

The post New Doosan 5-axis machine tool investment pays dividends. appeared first on CNC Machinery Solutions.

Somerset-based Watson Gym Equipment, one of the world’s leading manufacturers of specialist strength training equipment used in high-end PT gyms, has recently invested in two new Doosan machine tools and a Doosan collaborative robot (cobot) from CNC Machinery Solutions – the exclusive distributor of Doosan machine tools in the UK and Ireland.

Watson Gym Equipment, created by owner and managing director Simon Watson in 1999, acquired its first Doosan machine – a large-capacity Puma 4100MB lathe – in March 2020.

The 15“ chuck box guideway Puma 4100MB is a rigidly-designed and built machine suitable for a range of heavy-duty machining operations including interrupted cutting. The Fanuc 0iT-controlled machine is equipped with a high-torque 30kW/2,000rpm spindle, a servo-driven tool changer (12-position) and driven tooling capability (7.5kW/4,000rpm).

Since being installed the lathe has been used to machine the company’s Pro Olympic weight plates which are made from solid marine grade stainless steel.

(Weight plates are the flat discs located at either end of a weight bar to create a barbell or dumbbell used for weight training).

The Puma 4100MB investment

The acquisition of the Puma 4100MB lathe had an element of serendipity about it.

In late 2019 Watson Gym Equipment had approached its existing CNC machine tool supplier to discuss the best way to ramp up production of its weight plates in order to meet increased demand.

Initial discussions centred around the acquisition of a new large-capacity vertical turning lathe to machine the components but, with an anticipated delivery time approximately six months after order placement, the company decided to consider alternatives and approached CNC Machinery Solutions for help.

Says Simon Watson:

“We were clearly aware of CNC Machinery Solutions and knew that the company had a good reputation in the market for the technology it sold and the after-sales services it provided.

“We approached them to see if they could help with our specific machining capacity issue and, after an in-depth discussion, they recommended the Puma 4100MB – a large-capacity horizontal lathe that was available from stock, and that could be delivered and installed (virtually) immediately.

“Mills took the time to understand our business and bought into our business model and what were trying to achieve. They pointed out potential tooling interference issues that could occur by going down the vertical turning lathe route and, instead, demonstrated the productivity and flexibility benefits that we could expect to gain from investing in the Puma lathe. All of which, incidentally, have been correct.”

Weight plates

Watson weight plates can be supplied to customers in a range of standard sets (i.e.150kg, 250kg, 350kg and 500kg) with individual plates weighing between 5kg and 25kg.

All weight plates are machined to high accuracy and exacting surface finishes. They feature powder coated end plates that can be customised if required (i.e. with a customer’s logo or brand), and are supplied with a lifetime warranty.

A quick look at Watson’s weight plates, just one product range in its extensive portfolio, demonstrates the company’s commitment to quality and continuous improvement, and goes a long way in explaining its continuing growth and success.

Explains Simon Watson:

“It’s relatively easy, and cheap, to manufacture weight plates from mild steel and then zinc- or nickel-plate them to give a professional looking finish. However, after a short period of time, and through constant use, they will lose their lustre and the coating will peel, chip or discolour.

“Our business model is focused on manufacturing high-quality, high-performance and competitively-priced premium products and equipment that look the part and that stand the test of time. That’s why we use stainless steel for our weight plates.”

Stainless steel is also used for the company’s range of popular and best-selling (class-leading) dumbbell handles.

The Lynx 2100LSYB investment

In early 2020 Watson Gym Equipment, with demand for its dumbbells at an all time high, made the decision to increase its in-house production capacity and approached CNC Machinery Solutions for guidance.

Of particular concern was how to increase production of the company’s heavy-duty dumbbell handles which are available in different lengths (12” to 22”) with a 30mm grip.

Explains Simon Watson:

“Dumbbell handles are not complex components. They are machined from bar and cycle times are short.

“To meet increased customer demand we needed additional turning capacity… and we needed it fast.

“Having already established a good working relationship with Mills through the acquisition of the Puma 4100MB we approached them again with our requirement, and they recommended the purchase of a Doosan Lynx 2100LSYB lathe and a Hydrafeed bar feeder.”

The 8“ chuck/ 65mm bar capacity Lynx 2100LSYB is a compact, multi-axis turning centre equipped with a high torque main spindle (11kW/4500rpm), a sub-spindle (5.5kW/6,000rpm), a Y-axis (+/- 52.5mm) and driven tools (3.7kW/6,000rpm).

The machine is ideal for small part production and is fast, accurate and reliable.

The machine and bar feeder were installed at Watson Gym Equipment’s facility in early May 2020 and its production capabilities have recently been significantly increased still further with the recent addition and integration of a Doosan M1013 collaborative robot (cobot) which was delivered and installed later in the month.

The cobot, with its 10kg payload and 1.3m reach radius, is positioned in front of the Lynx lathe and is programmed to unload the finished parts (dumbbell handles) once machining operations have been completed.

Says Simon Watson:

“The job and machining process were ideal for automation. We can set up the job and leave the machine running unattended and overnight. As a consequence we have improved our productivity significantly and, because we have effectively removed the labour component from the process, have reduced the cost per part as well.”

Future developments

Watson Gym Equipment is constantly innovating and improving.

Plans are well underway to increase the company’s floorspace by an extra 22,000 square feet with the building of a new machine shop adjacent to its existing facility in Frome.

The new facility is expected to be completed by the end of the year (November/December 2020) and will house all the company’s CNC machining operations, including a new CNC Machinery Solutions ‘SYNERGi 25’ automated manufacturing cell.

The cell comprising a Puma 2600SY lathe (with Y-axis and sub-spindle capabilities), a 25kg high-capacity industrial robot, an automated two-way drawer system (for stacking storing and loading workpieces and finished components), a 17” touchscreen HMI, locating plates, pneumatic grippers and SICK safety systems has been specified and ordered to help the company meet growing demand for its word-class, indestructible dumbbells.

Says Simon Watson:

“Automation is the key to increased productivity, operational efficiency and improved competitiveness. The SYNERGi 25 cell will help us increase throughput and reduce bottlenecks, and enable us to exploit lights-out, unattended operations still further.

“We will be working with CNC Machinery Solutions’s automation specialists in the next few weeks and months to create and prove out a bespoke manufacturing process at their Automation and Turnkey Centre in Leamington prior to it being delivered to, and installed in, our new facility.

“In the past six months we have developed a strong and positive working relationship with CNC Machinery Solutions based on integrity and trust. The technologies they are able to supply and the added value consultancy they provide are helping us optimise our performance…making us fitter for the future.”

The post Fit for the future. appeared first on CNC Machinery Solutions.

CNC Machinery Solutions, the exclusive distributor of Doosan machine tools in the UK and Ireland, has supplied Cheltenham-based Ferrositi Ltd., a leading precision subcontract specialist, with a new, state-of-the-art mill-turn machine.

The 13” (quick-change) chuck Doosan SMX 2600S, a roller linear guideway multi-axis machine equipped with left and right opposing spindles (26kW 4000rpm), a 240 degree B-axis milling spindle (26kW/12,000rpm), Y-axis capability (+/- 150mm), a servo-driven ATC (40 position) and the latest Fanuc 31i control, was installed at Ferrositi’s 18,000 square foot facility in May 2020: a time when many companies were (understandably) battening down the hatches.

The investment made during the height of the pandemic outbreak is typical of Ferrositi – a company built on innovation and continuous improvement, and one committed to delivering engineering excellence and best-in-class customer service.

Says Nick Furno, Ferrositi’s managing director:

“Ever since the company was created (in 2012) we have invested in multi-axis machine tools as a route to improving our productivity, operational efficiencies and competitiveness.”

A quick tour of the company’s sizeable machine shop provides ample evidence of its investment policy with a number of advanced, large-capacity 5-axis machining centres and lathes, with sub-spindles and full miil-drill capabilities, in close proximity to one another.

Continues Nick Furno:

“We serve and operate in a number of global and highly-competitive sectors and industries – i.e. aerospace, oil and gas, automated and special purpose machinery, high-profile architectural projects.

“Central to our success in these, and other sectors, has been our ability to machine high-quality components and deliver them to customers…on time…every time…and within budget.

“The multi-axis machines we have at our disposal make us more efficient and enable us to make complex high-precision parts quicker… in fewer machining operations and, often, in one set up.

“We are always on the lookout to add to, and strengthen, our front line machining resources.”

Despite the lockdown such an opportunity arose in April 2020 and resulted in Ferrositi making its first investment in Doosan machine tool technology, and coincidentally its first mill-turn machine acquisition.

Explains Nick Furno:

“The Doosan SMX 2600S complements our existing machine tool portfolio.

“Both Doosan and CNC Machinery Solutions have good reputations in the market and, when I was informed that a mill-turn machine was viable immediately (from CNC Machinery Solutions stock) at a good, competitive price…I was interested.”

Having seen the SMX 2600S at CNC Machinery Solutions’s Technology Campus facility in Leamington the decision to purchase the machine was made.

Concludes Nick Furno:

“We have had the machine for about four weeks and, during this quieter-than-normal period, are spending time familiarising ourselves with its operations, functionality and its latest Fanuc control.

“Already we can see, and appreciate, that the machine is powerful, fast, flexible and accurate. We are particularly impressed with its rigidity, ergonomic design and thermal stability.

“Using a single set-up, the SMX is capable of performing multi machining processes. As a consequence this means we can reduce production bottlenecks and limit stop-start operations.

“The SMX will help us consolidate and grow our position in existing supply chains and sectors, as well as helping us to spearhead our move into new sectors and industries – i.e. machining components for the food processing and medical sectors.”

The post Continuous improvement never stops! appeared first on CNC Machinery Solutions.