A turned parts subcontractor has streamlined production with the addition of two multi-axis mill-turn centres for machining complex, high added value work.
Turned parts subcontractor, Qualiturn Products, has streamlined production with the addition of two Star SR-20RII multi-axis mill-turn centres. Its Hertford, UK, facility now boasts 15 Star sliding-headstock lathes, all of which are less than eight years old and of top specification in terms of the number of CNC axes, driven tools and traverse speeds. Owner Bernard Groom commented, 'In 2004 we lost three contracts for fairly simple components - none requiring reverse-end work - to subcontractors in China, India and Korea, but none in 2005.

We make sure that our plant is as modern as possible, allowing us to produce complex parts unmanned in short cycle times.

It means that we do not have to increase our labour costs, allowing us to stave off competition from low-wage economies.' He went on to explain that the latest Star machines are equipped with attachments for sub spindle slotting and for angle milling, drilling and tapping.

When installing a new lathe, he opts to buy most of the optional add-ons to provide maximum versatility and productivity when competing for complex, high added value work.

Qualiturn's policies are certainly paying off.

Since moving to its new, larger unit in February 2004, the company has seen a 20% increase in turnover, derived from a wide spread of 180 customers.

The aim is to produce all parts in one visit to a machine, otherwise it is difficult to make money in today's competitive environment.

Completion in one hit of what would have traditionally been second operations, such as cross drilling and reverse-end machining, is key to profitability.

Mr Groom pointed out that judicious use of backworking is particularly important, as it can be used to reduce overall cycle time for components that could be machined in the main spindle alone.

By allocating some operations to the sub spindle, the main spindle is relieved to start producing the next part earlier, thereby minimising the cycle time.

An advantage that UK subcontractors have over foreign competitors is the trend towards ever smaller batches, whereas having parts made in India or China requires large runs for them to be economical.

While Qualiturn typically produces batches in the region of 15,000-off, orders for 50-off are not infrequent - quantities that are far too small to have machined overseas.

Other work that is relatively safe is the production of components to tight tolerances; for example, a recent order for 5,000-off components stipulated that +6/-0 microns, be held on a 5mm turned diameter.

Continued Groom, 'Qualiturn is bucking the trend by growing in a contracting industry, partly because turned parts subcontractors around the country are going into receivership or simply closing their doors because they cannot make a reasonable living.

In either case, the reason is likely to be that they have not invested in modern CNC machines like Star sliders.

The other factor in our favour is that we make a point of training our own setter / operators in-house, whereas all too often, manufacturing industry in the UK neglects this and tries to recruit from a diminishing pool of qualified engineers.

However, a little investment in training results in people wanting to join your company, and in their being productive very quickly because they are familiar with your machines and procedures.' His view of British subcontracting is that the prospects are bright provided that firms do not try to compete for orders involving large batches of simple parts, such as those traditionally made on cam auto's or conventional multis.

Manufacture of complex parts costing pounds rather than pence is undoubtedly the future.