Easy-to-use conversational programming routines on a manual/CNC lathe have made a significant difference when applied to the small batch work, says a precision machining company.


If one event in its 52-year history could be said to encapsulate Ilford Engineering's tradition of engineering excellence, it would be the 1995 Le Mans 24 hour endurance race. The winning car featured engine, brake and body components produced by the company, and the achievement is still regarded as a defining moment in terms of the precision and reliability of this Basildon, Essex sub-contractor's output. Indeed, the round-the-clock demand for its engineering expertise is such that the 65-employee company continues to operate a night shift.

Ministry of Defence approved since 1973, Ilford Engineering's reputation has ensured its involvement with a diversity of projects, from 'supercars' and body scanners to Challenger tanks, where Ilford components have been used in a computerised suspension system.

'The advantage we have is that we operate in niche markets,' says Chris Greenhalgh, Ilford's Production Manager, 'which means a high percentage of repeat orders and a lot of scheduled work that could entail making the same part for, say, five years.' Even so, batch quantities tend to be small, with prototype and development work benefiting from a 'one-stop-shop' combination of precision machining, fabrication and assembly.

It's also an environment where, with motor sport customers in particular demanding both precision and fast response, CNC milling and turning machines supplied by XYZ Machine Tools have found their niche, their 'prompted' conversational programming proving to be an especially useful attribute.

The latest acquisition is a 7.5 HP/5.6kW Proturn VL 355 manual/CNC lathe that has replaced a manual centre lathe.

Machinist John Knight describes the new machine, which has a 360mm swing over bed and a 52mm spindle bore, as 'fast and accurate, holding [tolerance] limits well'.

And he says the easy-to-use conversational programming routines of the Prototrak VL control have made a significant difference when applied to the small batch work, usually up to 20-off, earmarked for the new machine.

When programming the Prototrak VL CNC, the operator simply inputs the geometry that is required before then filling in the prompts.

And, having defined the part geometry and stock dimensions, the tool path, including all roughing passes and the speeds and feeds, is then generated.

Constant surface speed is an integral feature of the Prototrak VL's software, as is spreadsheet editing which caters for extensive changes to large programs.

At Ilford Engineering, the time taken to program from drawing to finished component can be as little as ten minutes, which in a fast-moving business is a considerable benefit.

Typical of the type of work being tackled on the Proturn is a batch of one-metre long, zinc plated steel tubes and complementary white nylon collars destined for a sister company, Miltra Engineering, specialising in training and multiple munitions sets (TAMMS).

Once machining is completed, the three sizes of tube are telescoped together and incorporated into replica munitions.

Civilians and military personnel around the world depend on these inert devices, which are entirely free from explosive or incendiary materials, when being trained in recognition, awareness and disposal procedures.

Currently engaged in updating its BS EN ISO 9002-1994 accreditation and aerospace approvals, Ilford Engineering attaches considerable importance to innovation, experience, up-to-date technology and, above all, quality workmanship.

Which is why the company's customer list includes such 'blue chip' names as British Aerospace, Thales and Lotus Cars.

'It's about getting quality parts out of the door and keeping the customer happy,' says Chris Greenhalgh, 'but in these days of the 'cost down' culture, you have always got to be asking 'why are we doing it this way?' and 'how can we do it better?' You can't wait for a customer to answer these questions, because by then the work could be on its way to someone else.'