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ISSUE 03Oct 2016

£1m factory extension PP presses the button on ambitious expansion

One of the West Midlands’s fastest growing manufacturers is dismissing uncertainty surrounding Brexit by investing more than £1m on a new factory extension.

PP Control & Automation has pressed the button on ambitious expansion plans that will see it add 1,000 sq metres of production space to its existing site in Cheslyn Hay, including a new logistics department and clean assembly area.

Construction work has already started on the building in a move that will give the company the additional capacity it requires to achieve its target of doubling sales turnover to £40m by 2021.

New staff are in the process of being recruited for the first phase of expansion, with the control and automation specialist keen to invest in six new apprentices as part of this recruitment drive.

PP £1M FACTORY EXPANSION OEM OUTSOURCING BROCHURE RELEASED FORGING THE FUTURE

“There was a lot of talk about uncertainty holding back industry after the Brexit vote, but we have confidence - in the medium term - that UK manufacturing in general will be strong and the growth plans of ourselves and our customers remain unchanged,” explained Tony Hague, Managing Director.

“In the short term with Sterling weakening against the euro and the US dollar, we have actually seen growth in export markets as UK competitiveness has improved.”

He continued: “The additional 1,000 sq metres will be used for additional manufacturing space, a just-in-time logistics operation and new clean assembly area that we’ll need for new opportunities in the more specialist industry sectors, such as scientific equipment and semiconductor processing markets.

“Importantly, it gives us the manufacturing footprint required to increase sales by 100% and is a real show of intent when talking with potential clients.”

PP Control & Automation, which is a member of the Manufacturing Assembly Network (MAN), has become one of the world’s most respected suppliers of electrical control systems, cable harnesses and sub-contract manufacturing solutions.

Employing nearly 200 people, the company has benefitted significantly from the ‘outsourcing’ trend being employed by machinery builders keen to reduce production lead times, secure greater manufacturing flexibility and ultimately reduce overall manufacturing costs.

> MECHANICAL BUILD AT PP CONTROL & AUTOMATION’S CHESLYN HAY SITE

www.man-group.co.uk +44 (0)845 034 6676

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> CONTINUED ON PAGE 2.

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Issue 03 October 2016

www.man-group.co.uk +44 (0)845 034 6676

PP expansion story continued

@GraysonTS@man_group_

“Companies have realised that strategic outsourcing in areas of non-core activities offers many significant commercial and operational benefits, but they have to make sure they fully investigate their choice of outsourcing partner. Get it wrong and the consequence can be devastating,” explained David Fox, Chairman of PP Control & Automation.

“Manufacturers are more aware of the processes that they wish to keep in house, these are a core activity and key to their success and the areas they wish to invest in.

“Equally they observe non-core activities as being unnecessary and often a cost burden.

“This awareness is something we’re now looking to capitalise on through our involvement with the Manufacturing Assembly Network.”

He concluded: “Working in partnership with electronics experts SMT Developments and fabrication specialist Mec Com, we have launched the OEM Outsourcing Cluster and will be promoting this through a new brochure, digital marketing campaign and by attending carefully identified trade shows.”

PP Control & Automation, which holds ISO 9001:2015 and UL 508A accreditations, is targeting growth in Germany, the US and North America as part of its push for £40m sales.

C. BRANDAUER & CO. LTDSince Brandauer was founded more than 150 years ago, it has evolved into one of the largest contract presswork and stampings companies in Europe, manufacturing high speed precision stamped components, in difficult materials, for a wide range of industry sectors worldwide.

The company offers the complete range of services required for the supply of pressed metal components: from prototyping, design and in-house tool production (or a specialist tool transfer service) through to high-quality manufacturing and logistics.

PR FILECOMPANY

> LATEST PRODUCTION TECHNOLOGY: 5T to 125T PRESS RANGE

Sector insight: Electronics

> TONY HAGUE, MANAGING DIRECTOR, PP CONTROL & AUTOMATION

PLANT & CAPABILITYn Wire EDM (Fully interfaced with the appropriate CAM software)n Modern presses (5T -125T) including Bruderer, Haulick Roos, Hydraulic and Hydro- Pneumatic Hare presses, Seyi and Minstern Advanced 3D CAD and designn Environmentally friendly cleaning processesn World-class quality management systemsn Prototypesn Special Products Division offering one-off component projectsn Fully-equiped secondary operations sectionn Development, production and maintenance of new tooling and transfer of existing toolingn Laser markingn EMC Shielding

> PRECISION PRESSINGS & STAMPINGS

CONTACTRowan Crozier (CEO)

t +44 (0)121 359 2822 e rcrozier@brandauer.co.ukw brandauer.com

@GraysonTS@cbrandauer

Control & AutomationComplete manufacturing solutions

CONTACTTony Hague (MD)

t +44 (0)1922 419 109e tony.hague@ppcanda.comw ppcanda.com@GraysonTS@ppcanda

The UK is proud to be the home of the 5th largest electronics sector in the World. Many of the MAN Group members regularly supply this industry and can collectively provide a full service.

ELECTRICALCONTROLSYSTEMS

CABLEHARNESSES ELECTRICAL

ASSEMBLIES

PLASTICINJECTIONMOULDING

STAMPING

SHEETMETALFABRICATION

ALUMINIUMCASTINGS

PCB

Brandauer will be heading to electronica in November, find the company in Hall B2, Booth 541

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‘Outsourcing’ could deliver £5m boost to MAN

man-group.co.uk

SINGLE SOURCE SOLUTIONS FOR OEMs

MECHANICAL, PNEUMATIC, ELECTRICAL AND ELECTRONIC ASSEMBLYOUTSOURCING

DOWNLOADBROCHURE

Richard Bunce (MD)t +44 (0)1889 272 147 e sales@mec-com.co.ukw mec-com.co.uk mec_com_ltd

3 man-group.co.uk

MAN’s Original Equipment Manufacturer (OEM) cluster features industry leaders in fabrication, electronics and electrical assembly, who have worked together on a number of projects to deliver outsourcing solutions to OEMs across the world. By sharing its resources, knowledge and expertise, the cluster provides unique access to a manufacturing service that reduces lead times, increases capacity, solves complex production issues and cuts costs.

Find out more about the companies behind the OEM cluster.

With shared knowledge, you get a greater return on your outsourcing

investment

Established: 2000

Turnover: £14m

Workforce: 200

Factory: 550,000 sq ft facility in Staffordshire and a 350,000 sq ft operation in Romania.Services provided: Sheet metal fabrication, coil winding, electronic and electromechanical assembly and test.

Industries served: Power distribution, food processing, medical, renewable energy and machine tool.

Technology: nNew generation fibre laser with full automation

nLatest punch press technology, incorporating automated load unload capacity

nDedicated in process and final assembly testing cells

Countries exported to: Australia, France, Germany, India, Poland, Tunisia and USA.Did you know? In order to support further outsourcing by new and existing customers, Mec Com is committed to the acquisition of Auto panel bending and robotic welding capabilities.

Operating from two state-of-the-art manufacturing sites in the UK and Europe, Mec Com offers a total manufacturing solution to a growing global customer base.

Investment in new technology and the skills of its workforce has seen it become a strategic partner for clients looking for sheet metal fabrication, coil winding, electronic and electromechanical assembly and test.

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> HIGH LEVEL MACHINE ASSEMBLY

AT PP CONTROL & AUTOMATION

Introducing the Manufacturing Assembly Network

Between the unique collective, it has over 50 years’ experience

of managing outsourced production for global names in many

diverse industries, including automotive, electronics, food and

drink, packaging, printing, renewables and telecommunications.

A commitment to investment in new technology and its people

has seen The MAN Group work with some of the world’s largest

manufacturers, delivering cost, time and capacity benefits

running into tens of millions of pounds every year.

Our OEM cluster is driven by Mec Com, PP Control

& Automation and SMT Developments, supported

by other group members offering castings, CNC

machining, design, forging, injection moulding

and high volume precision pressings.

A group of eight world class sub-contract manufacturers

and a specialist engineering design house

man-group.co.uk

SINGLE SOURCE SOLUTIONS FOR OEMs

MECHANICAL, PNEUMATIC, ELECTRICAL AND ELECTRONIC ASSEMBLYOUTSOURCINGFind out more about:nimproved productivitynreduced manufacturing costsnimproved manufacturing lead times

Issue 03 October 2016

www.man-group.co.uk +44 (0)845 034 6676

The Manufacturing Assembly Network (MAN) is looking to target more than £5m of new contract opportunities after launching a new cluster to tap into the demand from larger companies for greater levels of strategic outsourcing.

Mec Com, PP Control & Automation and SMT Developments has joined forces to give original equipment manufacturers (OEMs) the chance to access fabrication, electronic and electrical assembly services through a single source.

It comes after the trio saw a 25% increase in the number of outsourcing ‘wins’ secured over the last twelve months and will provide a new dedicated resource for clients looking to outsource non-core activity, whilst investing more resource on critical manufacturing operations.

By sharing its resource, knowledge and expertise, the cluster promises to reduce customer lead times, increase capacity and reduce overall production costs.

“Every year we set out a 12-month strategy for growing the MAN Group and this time we decided to focus on splitting into clusters to target specific customer groups,” explained John Rowley, Managing Director of electronics manufacturing specialist SMT Developments.

“The first cluster that immediately leapt out was providing outsourcing solutions to OEMs, something we were doing individually and occasionally together. There is definitely a trend towards the more progressive firms looking to recognise non-core activities within their business and identify supply chain partners that have greater expertise.”

He went on to add: “The benefits are many, including stock and work in progress reductions, greater production flexibility and eliminating the need for scarce and costly skilled sub-contract labour. However, the main driver is reduction in production and sales lead times for our customers, this is a common theme across all sectors.”

MAN will make the most of this new cluster by embarking on a six-month marketing campaign to target potential customers in automotive, food processing, machine tools, packaging and the energy sectors.

A twelve-page brochure and digital media campaign has just been launched and the collective is now looking to attend a number of specialist shows and is considering taking the ‘outsourcing’ offer on the road.

Richard Bunce, Managing Director of fabrication experts Mec Com, continued: “A lot of people offer outsourcing, but very few can offer a single source to fabrication, electronics and electrical assembly. That’s what makes this different.

> OEM OUTSOURCING BROCHURE NOW AVAILBALE FOR DOWNLOAD

@GraysonTS@man_group_

“We have worked on numerous contracts together and understand the way each firm works. For the customer, you just get one lead member who controls the complete interaction. The feedback has been great.”

He concluded: “Better still, we can then call upon the expertise of an engineering design consultancy and five other sub-contract manufacturers offering casting, CNC machining, forging, injection moulding, pressing and stamping.

“Customers already benefiting from the MAN difference include a leading aerospace technology provider, a specialist in screen printing and a fruit labelling expert. All are best in class and adopting the ‘outsourcing’ approach to growth.”

The Manufacturing Assembly Network offers customers access to 800 highly skilled staff working across 15 factories in three continents.

It spends more than £5m on new technology and capital equipment every year and currently exports to 35 countries.

Other member companies include Alucast, Barkley Plastics, Brandauer, Grove Design, KimberMills International and Muller Holdings.

Control & AutomationComplete manufacturing solutions

CONTACTTony Hague (MD)

t +44 (0)1922 419 109e tony.hague@ppcanda.comw ppcanda.com

CONTACTJohn Rowley MBA (MD)

t +44 (0)1926 453 050e johnr@smtdevelopments.co.ukw smtdevelopments.co.uk@GraysonTS@smtdevelopments

@GraysonTS@ppcanda

CONTACTRichard Bunce MSc (MD)

t +44 (0)1889 272 147 e richard.bunce@mec-com.co.ukw mec-com.co.uk@GraysonTS@mec_com_ltd

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Forging the futureLarry Joyce, Chairman of KimberMills International, explains why technology is helping his firm forge ahead.

Issue 03 October 2016

www.man-group.co.uk +44 (0)845 034 6676 @GraysonTS@man_group_

Forging is one of manufacturing’s most traditional art forms and one that is often seen as being a bit slow to embrace the future.

In fact, it’s often described as a case of ‘evolution’ rather than revolution when it comes to our sector, but that is slowly beginning to change amid a raft of exciting developments.

Computer techniques are starting to allow the simulation of processes prior to capital investment and new materials are becoming commonplace on spec sheets. Then you’ve got lean burning furnaces, which offer the dual benefits of saving energy and reducing scaling resulting in a better surface finish.

At KimberMills International we are also doing our best to embrace the ‘revolution’.

£1m has gone into the development of a second state-of-the-art forge in Cradley Heath, which features a 70cwt hammer suite capable of producing forged parts up to 75kg…25kg bigger than our previous best.

We have also linked the process through a clearspace hammer and this has considerably enhanced our ability to handle complex parts.

The new facility is air-conditioned and boasts high-lux lighting and improved working conditions for our staff, which, in turn, has increased output levels/productivity. Our people remain the firm’s biggest asset so we need to look after them.

This was the largest investment in our 80-year history and an ambitious move when you consider our turnover. However, we knew it was necessary if we are going to compete with international rivals for new opportunities in automotive, petrochemical and rail.

And thankfully it is already paying off. Our customers have responded positively with many placing orders because they believe that our investment gives them confidence that ‘we are here to stay’.

Importantly, we have successfully reshored a product back to the UK that is worth £250,000 and rising. This was previously manufactured in Eastern Europe.

So while our industry may have its roots in the past we have recognised the need to move with the times.

Forging is still a crucial part of modern manufacturing and long may it continue.

KimberMills International is a manufacturer of specialist high quality forgings and finished machined parts, with companies located in Cradley Heath and Coventry.

> L-R: GEOFF TURNBULL (MANAGING DIRECTOR) & LARRY JOYCE (CHAIRMAN)

Muller boasts one of the largest privately owned subcontract operations in the UK, based across four world class facilities.

There has been significant investment in creating an unrivalled CNC milling, turning, multi-spindle and conventional escomatic capability.

With a highly skilled workforce - all trained in lean manufacturing – the company ensures it’s a critical partner to some of the world’s biggest tier 1s.

CA

PABILITIES FEATURE

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CNC PLANT CAPACITY: TURNING

n 6 x 65mm bar dia. twin spindle twin turret CNC lathes with live toolingn 3 x 50mm bar dia. twin spindle twin turret CNC lathe with live toolingn 2 x 42mm bar dia. twin spindle twin turret CNC lathes with live toolingn 2 x 42mm bar dia. twin spindle single turret CNC lathes with live toolingn 3 x 300mm dia. turning dia. heavy duty CNC chucking lathesn 17 x 200mm dia. turning dia. CNC chucking lathesn 6 x 16-32mm bar dia. CNC sliding head lathes with live tooling

CNC PLANT CAPACITY: MACHINING CENTRES

n 4 x twin pallet horizontal CNC machining centres – table size 400mm x 400mmn 4 x high speed CNC vertical machining centresn 4 x heavy duty CNC vertical machining centres n 1 x high speed CNC drill machining centre

CNC MACHINING

CONTACTGeoff Turnbull (MD)

t +44 (0)247 655 5559 e geoff@kimberdrop.co.ukw kimbermills.co.uk@GraysonTS@kimbermills_int

t +44 (0)129 927 2102e paul.bethell@muller-england.co.ukw muller-england.co.uk

CONTACTPaul Bethell (MD)

@GraysonTS@mullerengland