cbm ed11 2nd draft metal matters... · 2009-04-20 · restructuring of the business can take place....
TRANSCRIPT
Forging19th International
Forging
Conference
page 12
FastenersThe Titanic -
A riveting
storypage 11
EnergyPro Enviro
energy
challenge
page 6
Sheet MetalThe history
of
dry films
page 15
SteelThe outlook
for
stainless steel
page 21
w w w. b r i t i s h m e t a l f o r m i n g . c o m 1
W
Managingthrough aRecession
DIRECTOR GENERAL’S
R E V I E WCBM
S T A F F
Confederation of British MetalformingNational Metalforming Centre, 47 Birmingham Road, West Bromwich, West Midlands B70 6PY.Telephone: 0121 601 6350 Fax: 0121 601 6373
e are now technically in a recession and clearly tough timesare ahead. Although the manufacturing industry, and oursector in particular, is in better shape than when entering
previous recessions the need to trim back and batten down the hatches isalready here.
The automotive suppliers are predicting 15 to 20% reduction in schedulesacross Europe for 2009, this will have a massive impact on the sector andbelow I have tried to list some actions that may be useful.
Sir John Harvey Jones in his book Managing to Survive recognised thatmanagement style must change under these circumstances, he recommendedconverting as many fixed costs to variable costs thus anticipating that theeconomy may not bottom out for a long period.
The CBM already offer many ways to reduce your costs these include:
1. Reduced energy costs: Even if your contract still has months to runyou could still reduce your bills. By contacting or changing your brokeryou could achieve some of today’s reduced energy costs now in returnfor a longer contract.
2. Invoice financing: if you are still running a debtor book, which may beworth several hundreds of thousands of pounds, many financecompanies will buy this and release much needed cash. Many of thefirst tier suppliers to the OEMs are now in financial difficulties and couldgo at any time, so dedicate someone in the organisation to reducingthe debtor days now.
3. Asset financing: Equipment now paid for but still retains value can beused to raise extra cash. While interest rates are lower consider usingasset financing for any cost saving capital outlay.
4. Layoffs: It is possible in some circumstances to lay off workers withoutpay and without making the jobs redundant in the short term. This maybe an interim measure, but could save money until a properrestructuring of the business can take place.
5. Reduced hours: Employees may prefer to work less hours rather thanlose their jobs altogether, this has been successful at JCB to protectthe number of jobs.
6. Redundancies: The CBM subscribes on your behalf to Croner’sBusiness support helpline. Advice is free and unlimited so please usethis facility if you have any questions on redundancy procedure.Contact 08445 618133.
7. Change insurer: Get a new quote from our insurance broker, theinsurance market has been softening and one of our forging membershas just saved 25% by changing insurer.
At the CBM HQ we have the necessary contacts to help you implement any of the above suggestions. Please contact, in confidence, John [email protected]
John HousemanDirector General
PRESIDENT lALAN SHAW
DIRECTOR GENERAL lJOHN HOUSEMAN
COMPANY SECRETARY lGERALDINE BOLTON
FORGING SECTOR SPECIALIST lDR KEN CAMPBELL
FASTENER SECTOR SPECIALIST lDR JOHN NEWNHAM
SHEET METAL SECTOR SPECIALIST lADRIAN NICKLIN
CENTRE & EVENTS MANAGER lDR ALAN ARTHUR
ACCOUNTS lCHRIS SMITH
ADMINISTRATOR lDEBBIE YORK
MARKETING & COMMUNICATIONS MANAGER l
KIRSI LINTULA
DG
’s r
evie
w
DG’s review
w w w. b r i t i s h m e t a l f o r m i n g . c o mcontents2
1 Director General’s review1 CBM staff
news3 Servo'Steel' new business thanks to MAS-WM3 Sheet metal sector meeting3 Launch of accident reduction initiative3 Metals Industry Dinner4 New business bidding for sub-contract
& supply chain work - 2012 games
pricing5 Don’t put Corporal Jones in charge of pricing strategy
energy6 Pro Enviro energy challenge
environment8 Environmental footprinting - what is it?9 Fluid waste minimisation in metalforming applications
fasteners10 Largest aerospace
fastener manufacturer?11 The Titanic - a riveting story
forging12 19th International Forging Conference14 Company profile: Chesterfield Special Cylinders
Confederation of British MetalformingNational Metalforming Centre, 47 Birmingham Road, West Bromwich, West Midlands B70 6PY.Telephone: 0121 601 6350 Fax: 0121 601 6373Enquiries: Kirsi Lintula,
Marketing & Communications ManagerEmail: [email protected]: www.britishmetalforming.comProduced by: Group Information Services LtdTel: 01937 580400Web: www.gisltd.co.ukWhile every effort is made to ensure the accuracy and reliability of materialpublished in this magazine, neither CBM nor Group Information Services Ltdand its agents can accept any responsibility for the veracity of claims made by contributors in advertising or editorial content.The design and layout of this directory remains the property of GroupInformation Services Ltd, it must not be reproduced or transmitted to a third party without prior written consent. © November 2007.
THE CBM’s MISSIONTo be the principal representative of, and service provider
to, manufacturing companies in the UK metalformingindustries as they strive to improve their performance.
Benefits of membership – what’s in it for you Rebates on your Climate Change Levy (CCL)Free employment law helplineFree technical helplineFree publicationsFree H&S helplineMonthly market reportsDiscounted hearing and noise assessmentsDiscounted training packagesDiscounted insurance premiumsBriefings & seminarsRegular meetingsHealth & safety officer servicePrivate healthcare scheme
MembershipMembership is available to companies who
manufacture products in the UK, by metalformingprocesses, particularly those who are engaged in hot and cold forging, and the shaping, cutting andforming of sheet metal.
Associate membership is available to companiesand institutions allied to the manufacture ofmetalformed products.
To be part of the wider picture and be masters of your own identity…
CONTACT CBM NOW!ME
MB
ER
SH
IP
C O N T E N T S
11
sheet metal15 The history of dry films17 ICOSPA Congress 200819 Giving aluminium
the hot-cold treatment
steel20 Steel Business Briefing update 21 The outlook for stainless steel
cold rolled22 Company profile: Metsec - Working in a changing economy
automotive23 Metalforming: our future?
automation26 Rapid prototyping with the
“Dieless” machining system
business strategy27 Pricing for profit
business support28 New changes to discrimination law coming in
finance29 Maximising the value
of your business
training30 Surviving the credit crunch -
the lean imperative31 Apprentice press technician qualifies
health & safety32 CBM members - What you have to do
to comply with REACH regulations
insurance33 Medical & vocational rehabilitation cover with the CBM
CBM events34 An update of current & past events
CBM directory35 Full and Associate membership address listings
17
31
26
cont
ents
newsw w w. b r i t i s h m e t a l f o r m i n g . c o m 3
Futaba-Tenneco UK Ltd
Leonardt Ltdwww.leonardt.com
Musashi Autoparts UK Ltdwww.musashi.co.uk
SPS Aerostructureswww.spstech.com
welcome to our
M E M B E R S
new
s
Launch of accident reduction initiative
T he modern day metalforming industry has a remarkableaccident record, but we have not been complacent, ourHealth, Safety and Environment group is probably the most
active of all the CBM groups. At the quarterly meeting guestspeakers regularly update the delegates on common Health andSafety issues. At the recent meeting it was agreed to collect andanalyse accident statistics from the industry in order to identifythose common items and collectively benchmark the sector, thenpursue solutions to eliminate them. The initiative has been named‘Accident Reduction in the Metalforming Sector or ‘ARMS’, thiscan be seen as a long term project and only after several years willthe fruits of this initiative established. For further information,please contact, John Houseman at CBM on 0121 601 [email protected]
CBM held its quarterly Sheet Metal Sector meeting andvisit at the Covpress in Coventry on 30 September. Issuesdiscussed at the meeting included state of trade, material andenergy prices. The minutes of the meeting will be circulatedto all members.
The visit of the Covpress facilities started with the X83Nissan/Renault body in white components, which has been infor ten years. Members also saw during tour the largerstamped parts were made on two 800 tonne transfer pressesand in some cases using tooling made in the Far East andprogression presses making smaller stampings along with 400tonne manual presses operating ganged single stageoperations. The spotweld cells were robotic and manual witha lot of emphasis on Poke yoke.
Next meeting will take place on 11 December 2008, if any member company would like to host it please contact Adrian Nicklin at CBM:
tel: 0121 601 6350 - email:[email protected]
Metals Industry DinnerWednesday 8 April 2009Marriott Forest of Arden,
nr Birmingham
Guest Speaker: Carol Thatcher
Journalist, Author, Broadcaster & After Dinner Speaker
After Dinner Speaker:David Gunson
Former Air Traffic Controller
For more information or to book a place please contact
CBM on 0121 601 6350 or email: [email protected].
Servo'Steel' new business thanks to MAS-WM
One of the UK's largest steel processing plants havedeveloped expansion plans and increased plantefficiency with the help of the Manufacturing
Advisory Service - West Midlands (MAS-WM)
Servosteel, based in Dudley, contacted MAS-WM to discoverif building an extension would solve their problem of storingoverflow stock.
Specialist Manufacturing Advisor Peter Jones conducted areview of the premises to evaluate how space was beingutilised. Using six sigma techniques, such as value streammapping, he discovered that material was being unnecessarilydouble or even triple handled due to the lack of space available.An excess of stock was being stored on the shopfloor due tothe continuous flow of traffic throughout the factory, with up tonine articulated lorries arriving and departing every hour.
As a result of the project double handling of material hasbeen reduced by almost half, productivity has increased by38% and logistics have greatly improved. Peter also agreed thatan extension needed to be built allowing Servosteel to store asurplus of stock to accommodate for busy periods.
Jim Spencer, Managing Director of Servosteel, is delightedwith the outputs “We have seen clear, distinct results from theproject without any disruption to normal operations. We nowhave a long term strategy in place and will continue to utilise theexpertise we have received.”
Since the project Servosteel have applied for planningpermission to build an extension to their current premises andhave already secured new contracts that will increase turn-over by 38%.
To discover how MAS-WM can make a difference in yourcompany call 0845 245 0845 or visit our website at www.mas-wm.org
N E W
w w w. b r i t i s h m e t a l f o r m i n g . c o mnews4
new
s
10 DECEMBER 2008NATIONAL METALFORMING CENTRE
in association with West Midlands Business Council & Advantage West Midlands
NEW BUSINESS BIDDING FOR SUB-CONTRACT & SUPPLY CHAIN WORK - 2012 GAMESIn the runup to the 2012 Games there are a large number of contracts which require subcontract and supply chainproducts and services. We have invited the West Midlands Business Council to the National Metalforming Centre aspart of their regional activities to provide access to this work. They are sponsoring the event, which allows us to offerit to you free of charge. This Workshop which will inform and engage with businesses with the opportunities from the2012 London Olympic and Paralympic Games in a range of areas, including procurement.
Delegates will be briefed on:-
Which contracts businesses could consider bidding for;How to go about bidding for Olympic work;The worth and extent of Olympic work;What the Olympics can mean for your business;
There will be a series of speakers and packs will be available with further information at the end of the session.
TO RESERVE YOUR PLACE PLEASE CONTACT: [email protected]
13.00 Registration & Buffet Lunch
13.30 Welcome & IntroductionJohn Houseman, Director General, CBM
13.45 2012 OverviewJim Johnston, Advantage West Midlands
14.00 Contracts available and the bidding processJames Watkins, Executive Director, WM Business Council
14.15 Business Background to the London 2012 GamesPhilip Gray, Commercial Doctor Ltd
14.30 The International Sports Industry - UKTI SupportAndrew Bacchus, UK Trade and investment
14.45 Opportunities from using ITGrant Melrose, West Midlands Collaborative, Commerce Marketplace
15.00 Panel Discussion plus Q&AAll Speakers
£££:There is no charge for this event, but all delegates must register. Registration forms are available from CBM or download a form from www.britishmetalforming.com
CONFEDERATION OF BRITISH METALFORMING SEMINARCONFEDERATION OF BRITISHMETALFORMING SEMINAR
Confederation of British Metalforming | National Metalforming Centre | 47 Birmingham Road | West Bromwich | West Midlands B70 6PYTelephone: 0121 601 6350 | Fax: 0121 601 6373 | Email: [email protected] | Web: www.britishmetalforming.com
DON’T PUT CORPORAL JONES IN CHARGE OFPRICING STRATEGYBY CLIFF BURGIN OF BURGIN ASSOCIATES
Times are going to get tough. Volumes will undoubtedly shrink and customers will go out of business. Price pressure will be an inevitable part of the process. But yourapproach to pricing strategy shouldn’t resemble the Warmington–on-Sea Church Hallwhen the vicar rings the church bells.
Here are a few tips to bring some rationality into the situation:
W henever someone in your business says‘everybody is asking for price reductions’ askthem to sit down and calmly make a list of
exactly which companies, who in those companies andwhat exactly they said. There is a world of differencebetween a junior buyer in just one customer trying it on,and ‘everyone’. Remember anecdotes are different frommarket research.
If one of your salespeople insists that a particular customer willwalk if he does not receive a reduction, then ask him to findanother customer to whom you can increase prices to balance the books.
Get yourself on everybody’s tender list. All those prospects whohave told you in the past that they are not looking to changesupplier might just be thinking about it now. You never know theymay actually pay good prices.
Always ask what price they are looking for. Whether it is a newcustomer or an existing one asking for a reduction, get them to
put their cards on the table first. I have known plenty of supplierswho will not quote without a target price.
Be proactive with customers who are struggling. Go to them tosuggest ways of them saving costs, but make sure that saves you costs too.
Initiate a regular account review process with your salespeople.Sit down and discuss each customer in turn around once aquarter – how are we doing, is the business under threat, how can we make their life easier. If you are sure you are secure,consider a price increase on part of their business.
Watch your competitors. Now is the time to find out if they arestruggling with high gearing, losing volume or having problemsfilling capacity they have just brought on. This will affect theirapproach to pricing.
Now is the time to fix bayonets – just make sure that CorporalJones doesn’t stab you with his in the panic.
Cliff Burgin runs Burgin Associates a consultancy specialising in pricing
strategy and training. He advises business of every size on how to ensure
they maximise their profit through their pricing.
www.deritend.co.uk
costruzioni elettromeccaniche forni induzione
New Induction Heating Systems
Design
Installation
Repairs to All OEM Equipment
Tel 01922 621664
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pric
ing
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Pro EnviroEnergyChallenge
Environmental specialists Pro Enviro have helpedbusinesses in the West Midlands save thousandsof pounds by reducing their energy bills. In an
18-month project involving 25 small to medium-sizefirms, 50 jobs were created and £5,000,000 worth of new business was generated.
One company, Brockhouse Group, managed to save £30,000on its annual electricity costs alone.
The Accelerate Energy Challenge also safeguarded 125 jobsand £6,250,000 sales.
Companies from the automotive supply chain took part in theproject between January 2007 and June 2008.
A spokesman for Pro Enviro said: “We targeted these firms as being in the world's most demanding industry. They wereparticularly affected by increasing competition for business fromabroad, and by rising energy and raw material costs.”
The £450,000 Challenge was funded by regional developmentagency Advantage West Midlands, the European RegionalDevelopment Fund, and Accelerate. This organisation, managedby the Birmingham Chamber of Commerce, has helped over3,500 companies in the area to become more efficient.
The backing of these three organisations meant that Pro Environeeded to ask the companies involved for only a minimal contri-bution, typically £1,500, plus of course, their time and expertise.
The Challenge, which used several innovative techniques, wasconducted in three phases. To begin with, consultants from ProEnviro visited each business to evaluate its use of energy and howefficient this was. Then the company used its unique, monitoringand targeting process, EnviroTrack®, to track each company'senergy consumption.
The Pro Enviro spokesman added: “Particular effort was appliedto identifying out-of-working-hours and non-productive energyconsumption.”
Each firm was also given a “health check” with Accelerate'sBusiness Diagnostic, before an action plan was agreed.
And every firm had to choose either an energy “champion” or ateam to meet regularly on site with a Pro Enviro consultant. Thisempowered the companies to develop their own methods forsaving energy resources. Cost savings and pay-back periods werecalculated by Pro Enviro for each project.
The firms involved could also use Pro Enviro's innovative web-portal. This meant they could log on to a special members'section to view private company information, including data fromEnviroTrack®, and also to find out about new ideas andtechniques through Pro Enviro's Learner Management System®.There were also quarterly networking meetings, with presentationsfrom industry experts.
Advice was given to firms on what how they could improve theirresource efficiency, and on how to submit funding applications. Anaction plan was also mapped out for each firm for the next threeto five years.
Pro Enviro EnviroTrack - Brockhouse Group (142364500005) - EnviroTrack from Jan 08 - Mar 08, kWhr per 30 minute period
ener
gy
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ener
gy
At the end of the project, improvements in each company'sperformance were monitored, and savings, in terms of cash,kWhrs, and tonnes of CO2 were calculated.
The Pro Enviro spokesman added: “These firms benefited frombespoke monitoring and targeting of energy and resourceconsumption. The Challenge objectives, to improve efficienciesand reduce waste, were exceeded and the funding we securedmeant that paybacks were less than one year, in the majority of cases.”
Electrical energy savings achieved by Brockhouse Group weremonitored through the EnviroTrack® system.
Following the success of the Energy Challenge, Pro Enviro has been commissioned by Accelerate to set up three newnetwork projects focusing on energy, carbon and manufacturingimprovements.
Sector Project Undertaken Saving in kWhr (primary) Saving in tonnes CO2 Saving in tonnes C
Forging Compressed Air Controls 1,053,000 175 48
Forging Water Tower Controls 1,134,640 188 51
Ferrous Castings Repairs to Compressed 113,438 19 5
Air Systems
Anodising New Rectification Equipment 247,415 41 11
Forging Oil Quench 1,612,780 268 73
Forging Water Quench 784,680 130 36
Precision Engineering Reduce Non-Productive 142,350 24 6
Machine Operation
TOTAL 5,088,303 845 231
Pro Enviro EnviroTrack - Brockhouse Group (142364500005) - EnviroTrack from Jan 07 - Mar 07, kWhr per 30 minute period
Energy savings from some of the improvements are listed in this table:
FURTHER INFORMATION
http://networks.proenviro.co.uk http://www.accelerate-energy-challenge.co.uk
It seems a long time since the summer holidays,standing on the beach feeling the sand between yourtoes. Leaving footprints is part of our everyday life,
but how often do we consider the imprint of things that we buy? Here we explain the differences betweenecological and carbon foot printing, terms that are oftenused but not widely understood.
What is ecological foot printing?
Footprinting is a way of measuring the amount of productiveland and sea that is needed to provide the resources, such asenergy, water and raw materials we use in our everyday lives. Italso calculates the emissions generated from the oil, coal and gaswe burn, and it determines how much land is required to absorbour waste.
What's the damage?
In the Western World, 20% of the global population in richcountries consume 86% of the worlds resources. Thisdemonstrates how the development of the western world hasbeen a great cost to countries whose ecological footprints fit wellwithin a size that is needed to sustain them. The depletion of theozone layer is just one example of how the big feet of the westhave stamped on the rest of the world. Part of the ozone damageis attributed to pesticide use and greenhouse gases created fromthe consumption of fossil fuels.
For example…To consider the ecological footprint of a piece of jewellery youwould have to go right back to extraction of the piece of metal from the ground, transportation, processing, packaging,some more transportation, retailing, use, end of life, reuseand final disposal, and consider all of the resourcesinvolved in this.
To extract gold to make a 10gramme ring forexample takes 2tonnes of rock hauled up fromthe earths surface, 5tonnes of water, 30tonnesof air pumped underground to keep the minecool and enough electricity to run a large housefor several days. All of that before processing,forming and selling the ring.
Gold however, is possibly the best recycled com-modity of all elements and for that reason, compared to other metals, its footprint compares favourably.
What is carbon footprinting?
Carbon footprinting is a measure of the greenhouse gasesreleased as a result of an activity. These greenhouse gasescontribute to climatic changes. The most commongreenhouse gas is released into the atmosphere when fossilfuels (coal, oil, gas) are burnt. These gases and electricity canall be converted in carbon dioxide equivalent units, which willin turn make up a carbon footprint.
For example…Back to the piece of jewellery - when considering thecarbon footprint you would have to take into account the fossil fuels used to generate energy for extraction,processing, manufacturing, transport and distribution.You may also wish to consider the emissions associatedwith the supply chain.
How do I shrink my footprint?
Any organisation can get an idea about the size of their carbonfootprint by using an on-line carbon calculator. There are several of these available and they all have slightly different ways of calculating your carbon emissions. When you want to makecomparisons year on year, you need to ensure you use the samecalculator. (www.greenachiever.co.uk/carbonemission.asp)
The best way to reduce the size of your footprints, both carbonand ecological, is to identify where you can reduce the amount ofenergy, fuel or resources used to make your products or carry outyour everyday activities. Identify ways to reduce and manageconsumption of energy and raw materials while maintaining thequality and saleability of your products or services. This is the first step to making a difference to your footprint. It can also make good economic sense.
Some companies choose to offset their carbon footprint.Offsetting is a way of contributing to a carbon reducing schemesuch as tree planting or provision of energy efficient lighting in developing countries. Although offsetting may clear theconscience, it should be considered as the last resort afterreduction in consumption.
Counting carbon will become increasingly important andsomething that will be developed as climate change steps higher up the political agenda. Understanding it is the first step to controlling it.
www.e4environment.co.uk
envi
ronm
ent what is it?
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T raditionally two different types of lubricant technologyare employed for metalforming operations, a gear or
hydraulic oil for the machinery parts and a ‘drawing oil' forcomponent forming.
This is a process which has served industry well for many yearsand in some cases lubricant suppliers have benefitted from ‘totalloss’ applications. Water based forming technologies are alsoavailable offering significant volume advantages over the use ofneat oil. However, extended management time and costs arerequired in the use of aqueous technologies, concentrations mayhave to be maintained and there is the potential health risk frommicrobial activity.
Finally components are typically cleaned in aqueous solutionsdesigned to emulsify the oil or solvent based fluids to removeresidual lubricant films and particulate contamination from metaldeformation.
There have been limitations in the past whether due to cost orcapability on how fluids can be recycled with these approaches.Cleaning fluids become contaminated and require disposal andoils become cross contaminated reducing capability. However,with our increasing environmental responsibilities such limitationsshould be removed.
QSCD have taken a holistic approach to improve wasteminimisation by bring together a range of Lubricants, CleaningFluids and Recycling Technologies to minimise waste andmaximise recycling from metalforming operations.
Products within our Q-press lubrication range are engineeredfrom a core technology designed to replace both traditionalmachinery and metalforming lubrication methods. This is achievedwith a single lubricant, partly or wholly manufactured fromrenewable resources or with FSA approved raw materials to satisfya plethora of end user requirements whether they are in theautomotive, medical, personnel care, aerospace, communicationsor general industry sectors.
An example is in multi ram transfer press operations where botha gear and drawing oil, with viscosities of 150 cSt and 370 cStrespectively were replaced with a mineral oil based product from
the Q-press range with a viscosity of 46 cSt. No detriment tomachinery operation was evident and deep drawn componentswere produced to the same standards. An added benefit of usingmodern chemistry and raw materials in the Q-press range is athinner residual film on components requiring less dwell timeduring the cleaning process.
Cleaning products from the Q-clean range compliment the Q-press lubricants. Whether a non emulsifying aqueous or nonvoc solvent cleaning fluid is required, we also provide a range ofFluid Maintenance Solutions to enable analysis and onsiterecycling of fluids minimising or eliminating waste streams withproducts from the Q-filter range.
Q-clean Ultra is a high performance aqueous wash systemadditive manufactured from natural materials which cleancomponents from 1% concentration and at ambient temperature.
Q-clean EHP is a non VOC, hazard label free, bio-degradable,high performance solvent cleaning fluid which could be used toreplace existing hazardous solvents.
Our recycling technology is not limited to use with our fluids, ourFluid Maintenance Solutions can be used with current fluidsbringing immediate benefits to those processes where fluidchanges will require lengthy end user testing and qualification priorto production changes.
The Q-filter equipment range is designed to split aqueous orsolvent based fluids from oil with minimal environmental impact.We are also capable of maintaining the condition of fluids in use tomaximise their useful life.
QSCD are not just ‘barrel shifters’, our products and servicesare not solely for use with our own products as we are happy tointegrate them with our competitor’s products. We help developbest practice and improve fluid related processes and are pleasedour efforts have been recognised in reaching the final stages of the 2008 EDIE Environmental Awards in the Water & Waste Water Sector.
Fluid Waste Minimisation in Metalforming Applications
by Steve Thompson, QSCD Ltd
envi
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environment
www.gscd.co.uk
w w w. b r i t i s h m e t a l f o r m i n g . c o m
In August, Precision Castparts Corporation of Seattle USAannounced the acquisition of Airdrome Holdings, whichconsists of Airdrome Precision Components in California, and
AF Aerospace in Rugby, England. The acquisition is subject toregulatory approvals, but is expected to be completed by theend of 2008.
AF Aerospace manufactures precision machined, safety criticalcomponents for the aerospace industry, including ultra-high tensilebolts, fittings and fluid conveyance products in stainless steel, titanium,nickel alloys, aluminium alloys, and other special alloys. It is locatedclose to PCC fastener division’s existing UK plants, SPS Technologiesin Leicester, and SPS Aerostructures in Nottingham and Mansfield.
The addition of AF Aerospace to the SPS Technologies AerospaceFastener Division will be a natural complement to the group accordingto PCC chairman and chief executive Mark Donegan, “AirdromePrecision Components provides an immediate entry into the fluidfittings market segment, while AF Aerospace nicely complements ourUK fastener operations….both in product families and sales channels.Both of the Airdrome operations have significant growth potential, andwe expect to realise operational synergies and benefits fromeconomies of scale given our existing aerospace fastener facilitieslocated near both APC and AFA.”
Since PCC acquired SPS Technologies about 5 years ago, it hasadded several aerospace manufacturing companies to the group,including Air Industries, Shur-Lok, and Cherry. The division ranks asone of the largest manufacturers of aerospace fasteners in the worldand supplies all of the major airframe and aero engine manufacturers.
www.precast.comwww.spstech.com
p r o f i l eC O M P A N Y
fasteners
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LARGEST Aerospace Fastener Manufacturer?
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One of the authors, Dr Foecke, has been involved withresearching the metallurgical aspects of the tragedy for over tenyears, almost since the first pieces of the ship were brought to thesurface. He is a metallurgist with the US National Institute ofStandards and Technology, which has been associated with mostof the metallurgical investigations on this topic, so you have to takehis theories seriously. Rivets that have been retrieved from thewreck have been analysed by these researchers, and it has beenfound that they were made of wrought iron, but with a very largeslag content, almost 10%, which would have a major effect onmechanical performance. It is surmised that such rivets wouldfracture prematurely under the stresses imposed in the collisionwith the iceberg.
The rivets were being used at a time of transition in theshipbuilding industry from wrought iron to steel rivets, and thebetter steel rivets were used in the mid-sections of the ship. Theresearchers believe that the shipbuilders had difficulty sourcingenough high quality rivets, because they were building three similarships simultaneously, the Titanic and its sister ships, the' Olympic'and the 'Britannic', each of which needed about three millionrivets, so inferior fasteners were used for expedience.
This is not the only metallurgical problem that has beenidentified with the Titanic. The steels used in the skin of the shipwere not capable of withstanding impacts at very lowtemperatures. Samples of steel plate have been recovered fromthe ship, and when they were tested, they showed a severe lossof toughness at low temperatures. This is the “ductile-brittletransition” in steels, which was not known about until well after thedisaster. Steels that are quite tough and durable at normaltemperatures become brittle like glass at low temperatures. In thecase of the Titanic, the steel plates showed a transitiontemperature of over 30˚C. With the sea temperature being at -2˚C,it is believed that this phenomenon was responsible for the plateson the Titanic in contact with the iceberg cracking and fracturing,rather than deforming by bending. Modern steels have a transitiontemperature of -25˚C or better.
After the disaster, there were many improvements made to theway that ships were built and operated, to avoid any possibility ofa similar event. The metallurgical discoveries came much later. Andwhile the theory about the rivets is interesting, it has to be kept incontext. The sister ship 'Olympic' was retired from service afteralmost 25 years, and was built at the same time as the Titanic,using the same specification materials. The main difference is thatit didn't hit an iceberg!
t is nearly 100 years since the Titanic disaster, but that has not diminished the worldwide interest in
anything to do with it. You may have seen notices in the newspapers earlier this year about a new
book that claims that the poor quality of rivets used in the making of the Titanic was the main reason
that the ship sank. The book is titled “What Really Sank the Titanic”, and was written by two American
researchers, Timothy Foecke and Jennifer Hooper McCarty. Their claim has been disputed by Harland and
Wolff, the shipbuilders who built the Titanic all those years ago, but the authors say there is new documentary
evidence about the rivets that were used.
I
BY DR JOHN NEWNHAM, CBM
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d) The slowdown in the U.S. economy has impacted Canada andMexico, the major trading partners of USA. Both have seen areduction in the manufacturing sector and forging markets,especially automotive and light truck. The continued strength ofboth Canada and Mexico is in natural resources, energy, oil andmining. The Canadian dollar has turned higher against the U.S.dollar, blunting its previous trade advantage, but the slowdownin Canada is forecast as mild. 80% of Mexico's exports are toUSA and its slowdown will put constraints on Mexico'scontinued growth. Oil pricing is volatile and is a key factor, alongwith the financial and housing situation in the U.S. for continuedgrowth in Mexico.
2. Forging Industry ProfileTotal forging output in North America during 2007 was
estimated to be in the range of $12-14 billion.
The industry embraces all process, material, temperature andorganisation types whose products are manufactured and sold either on a custom, captive (in-house), standard product, or catalogue basis. Custom forging companies are mostlyindependent, small-to-medium sized privately owned businesseswhich produce forgings on a "made-to-order" basis. The size ofthe custom forging industry is approximately 295 operating plants.This includes 195 impression die, 65 open die and 35 seamlessrolled ring facilities in the United States, Canada and Mexico.
Aggregate production of the "custom" industry in 2007 isestimated at $9.4 billion sales value. From 2004 to 2007, therehave been increases of 25% in impression die forgings, 98% in open die forgings and 139% in seamless rings. Totalemployment is believed to be near 30,000 workers.
The largest Impression Die producers include, Alcoa;American Axle and Manufacturing; FormTech Industries;Hephaestus Holdings, Inc, (HHI); Ladish; ThyssenKrupp; Wyman Gordon.The largest Open Die producers include, The Ellwood Group;Patriot Forge; Scot Forge; Standard Steel; Weber Metals.The largest Rolled Ring producers include, Carlton Forge;Firth Rixson companies; FRISA; Ringmasters; Scot Forge.
3. Market SituationAs the U.S. economy has slowed, manufacturing and forging
industry markets have also lost momentum, but generally at alesser rate. While the automotive, housing and constructionindustries have experienced negative growth rates, most othermanufacturing sectors, e.g., durable goods have remained stableto continuing strong. Continued growth in offshore economies,and forging exports thereto, has helped to hold up the U.S. andNorth American forging and manufacturing sectors. Theweakening U.S. dollar has raised the cost of imported goods buthas made U.S. products less expensive in global markets.Discounting the effects of currency exchange, many NorthAmerican producers also report that significant forging volume,previously lost to offshore competitors, has returned to thedomestic industry for reasons of quality, delivery performance andbetter cost competitiveness.
Aerospace outlook remains very strong through 2010 andbeyond. 2007 was a record year for aircraft orders as Airbusnetted 1340+ new orders and Boeing 1400+. Air travel in theemerging economies of Asia is on the verge of exploding, creatingunprecedented demand for commercial aircraft. Despite therunaway cost of jet fuel leading to major restructuring of westernairline companies and operations, the need for more fuel efficientengines and aircraft to replace the aging fleet across the world
19th19th BY DR KEN CAMPBELL, CBMEconomic Report: AmericasINTERNATIONAL FORGING CONFERENCE
T he 19th International Forging Conference washeld in Chicago during 7-9 September, 2008.The event attracted 750 delegates from 26
countries; 19 technical papers were presented and 20forging industry suppliers participated in the concurrentexhibition. The UK was represented by eight delegates.
Following the conference, 16 forging companies hosted planttours ranging from Detroit to Los Angeles. Overall, theconference was well organised and well received.
During the conference, economic reports covering theAmericas, China, India, Japan/Asia and Europe were presented.Extracts from the report of the Americas are summarised below.Copies of the other economic reports are available from theCBM. Clearly, these reports were compiled before the currentworld banking crises. Summaries of the technical papers will bepublished in future editions of Metal Matters.
1. Economic TrendsAfter four years of strong growth, the overall U.S. economy
has slowed significantly since October 2007. While nottechnically in a period of negative growth, many observersbelieve the U.S. is currently in a mild recession. Principal factorsbehind the slowdown are;
a) The "sub-prime" mortgage loan crisis which has reverberatedthrough global financial markets. Consequently, consumerspending, which drives 70% of the total U.S. market, hasweakened due to tighter credit terms and energy, oil and foodinflation, adding to the economic slowdown and demand forproducts. Also, political rhetoric from Presidential electioncandidates is being used to remind the electorate of economicdistress for political gain, raising concern that it will lead to self-fulfilment.
b) U.S. unemployment in 2008 has risen sharply for six monthsin a row (Jan-June). At over 6%, it is at a level not seen in morethan 5 years; many observers feel the true figure is above 7%.Some four million U.S. manufacturing jobs have been lostsince 2000, many in basic industries including steel,automotive, metalworking and companies that are directcustomers of the forging industry. While some jobs have beenlost to improved productivity and technology, many have beenlost to restructuring of manufacturing within the U.S. and/ormovement to lower-cost, offshore countries. The contributionof U.S. manufacturing to total U.S. GDP has dropped from15.5% in 1997 to 12.9% in 2002 and to 11.7% in 2007,signalling an increasingly lower importance of manufacturingto the American economy.
c) U.S. trade imbalance, which peaked in 2006 at $811 billion(6.1% of GDP), has begun to abate with the slowdown inconsumer and business spending in 2007/08. However,purchases of manufactured and consumer goods and stillgrowing imports of commodities and petroleum products havediverted trillions of U.S. dollars offshore and away fromproductive domestic needs and investment. A consequenceof the trade imbalance and attendant deficit spending by theU.S. is not only higher inflation, but a weakening of U.S.currency, which has registered a decline in value by nearly40% since its 2002 high. The lower dollar value has served topush import costs ever higher, contributing to rising inflationduring the expansion of 2003-06, and culminating in the pastyear in record oil, energy and commodity costs. Despite U.S.Federal Reserve Bank attempts to maintain core inflationbelow 2.0%, currently it is closer to 4%; some say 5%.
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continued from page 12.... remains high. Some 28,000commercial aircraft are projected to be built anddelivered in the next 20 years. A continued majorconcern is the availability and cost of aerospacematerials including nickel, titanium and aluminiumalloys. Aerospace demand is high for both traditionalcommercial and military markets though defencespending could come under pressure following theupcoming elections. The general aviation andbusiness jet market is strong, particularly in theemerging "very light jet" sector where many newentrants have been announced.
Forging companies report (May 2008) the NorthAmerican automotive and light truck market to bedown by >20%. Demand for SUV and pickup truckshas taken the biggest hit due to the increased cost offuel and oil. Total vehicle sales of passenger cars andlight trucks, which edged close to 17 million in 2005,is forecast to drop near or below 14 million in 2008, with only slightincrease forecast for 2009. North American production oftraditional trucks and SUV's alone is forecast to drop to 3.5 millionvehicles by 2014, half the amount from the peak in 2004. It isbelieved that high fuel prices will have a permanent, structuraleffect on this market and that annual pickup/SUV sales won'treturn above 2 million vehicles per year.
Major breakthroughs in cost containment and restructuringrelative to plant and workforce size, employee wage, health,pension, retiree benefits and legacy costs, both by the automotivecompanies and their forging suppliers, have been insufficient tooffset higher costs of materials, energy, commodities and thefalling off of demand for vehicles. Forging suppliers report avariable situation based on their mix of product made for cars ortrucks ...in 2008, North America cannot seem to build enoughsmaller, more fuel efficient passenger cars, while light trucks andSUV's are again subject to promotional discounts to clear excessunsold inventory.
With the declining value of the U.S. dollar, the trend ofautomotive manufacturers and their forging suppliers from Asiaand Europe to set up operations in the U.S. and North Americahas continued. Domestic forging companies have, however,continued to penetrate and increase sales to these offshore-basedcustomers. Much of the future growth of the North Americanautomotive forging industry will come from further consolidation ofthe supply chain, and toward serving customers' needs inexpanded offshore and global markets including China, India andSouth America.
Forging sales to the heavy truck segment peaked in 2005-2006,but fell off in 2007 and into the first half of 2008, due to "pre-buying" to beat new environmental diesel emissionregulations and a weakening of goods traffic in a slowing economy,plus rising diesel fuel prices. While some rebound in the secondhalf of 2008 was expected, the impact of fast rising fuel costs hasclouded that forecast. Demand is expected to pick up again in advance of further new environmental emission regulations in 2011.
Off Highway is expected to be very strong through 2008 and2009, with significant sales and growing opportunity on a globaland export basis.
Peak years for rail were 2004-06 to build new rail cars for theincrease in freight traffic of both domestically-produced goods anda booming level of imported goods. The market has fallen off in2007-08, but remains at a "high/constant" level. Future growth issubject to renewed attention by investors and government as railremains an unfulfilled market and a less expensive alternative forboth freight and passenger traffic vis-a-vis cars and trucks and therising costs of oil and diesel fuel.
World demand for oil, commodities, energy, and mining remainsvery strong. Continued high oil prices will encourage U.S.domestic exploration, drilling and production efforts, limited only by
political and environmental roadblocks to development of offshoreand Arctic National Wildlife Refuge resources.
Power generation remains strong in all categories from small,portable units to larger industrial grade diesel backup systems and to land based turbine steam/gas systems for the electricpower grid. Demand for renewed use of nuclear power, whilecontroversial, is growing. The North American industry is heavilyinvolved in serving global expansion of power infrastructure on anexport basis.
Wind power is making significant inroads to the North Americanmarket and customer interest in recruitment of a domestic forgingsupply chain is a strong new trend item to report.
Agricultural and farm commodity markets remain strong, bothfor food and bio-fuel use.
Global demand for export of machinery for manufacturing,machine tool and steel industries, particularly in China and Asianmarkets, remains strong.
4. Steel & Material SupplyMaterial supply is tight in the United States, but better than the
pickup in 2004, when many forging companies were on allocationto buy material from a then recovering steel industry. Demand forforging grade material has dropped off only slightly in the upwardtrend of sales since then, particularly for auto and housingmarkets, due to the current economic slowdown. But pricesremain high, at record levels, principally due to continuing higherprices paid for iron ore and alloying elements, and steel maker'sincreasing costs attributed to energy, freight and transportation. Asa rule of thumb, customer steel prices have approximately tripledin the past 5 years.
After a relatively stable period in 2007, carbon steel pricesexploded again in early 2008 with some spot prices increasing40% to 50%. Pricing pressure for material remains severe. Asworld demand for steel continues on the upswing, material pricingis not expected to fall significantly in the foreseeable future, evenas various and individual economies slow or turn down, or ifcommodity prices fall or moderate. Long term purchase contractsfor material are less frequently negotiated without regular provisionfor surcharges. A trend has emerged whereby smaller quantitiespurchased are often quoted at prices "when delivered".
Steel and other forging grade materials are exhibiting high coston a worldwide basis. Aluminium, Nickel, Titanium, Molybdenum,and Chromium reached record levels in 2007 and remain at or nearrecord levels. The weaker dollar has added pressure to the cost ofmaterials imported to the U.S. The forging industry has expressedconcern that domestic prices are higher than global pricing levels,although material companies report that from a cost basis, theirselling prices have evened out in global markets. Whether or notmaterial price increases remain or "stick" at current levels isincreasingly a variable as customers reach a tipping point inslowing economies and refuse
19th IFC delegates during plant tour of A.Finkle & Sons Co., Chicago.
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CChesterfield Special Cylinders' Chief Executive, JohnHayward (above), now goes through to the national finalon October 6th. John modestly told his audience, at the Manchester ceremony, that the real credit for the
award should go to everyone at the Sheffield firm, and its quotedholding company, Pressure Technologies plc.
CSC designs, manufactures, tests and refurbishes speciality, high-pressure, seamless-steel gas cylinders, for global energy and defencemarkets.
John - who had led CSC's management buy-out in 2004 - broughtthe century-old business to the Alternative Investment Market in June2007, and its shares have trended steadily upwards, despite continuedmayhem in the equity markets.
John was originally brought in to CSC as Finance Director ten yearsago, following spells with Boots, Courtaulds, United EngineeringSteels, and T&N, and his experience with the latter company has beenof particular value.
“Essentially, we have been introducing techniques used inautomotive supply chains to a traditional manufacturing business,” hesays.
CSC has benefited significantly from investment in both workforceskills and new technology, and John says theexpansionist strategy followed a realisation that itwas losing potential business, to its own customers.
“We were seeing them take our cylinders toEurope, fitting valves, leak-testing the assembly,then shipping them to their customer. We knew we
could do the work, and ship direct to their customer for them, but weneeded to up our game,” he recalls.
New training programmes ensured every shop-floor worker had aminimum of NVQ Level 2 qualifications, whilst the recruitment ofadditional qualified staff ensured the full benefit could be gained,from £500,000 of handling and leak testing kit.
Enterprise Resource Planning software was then installed, togenerate further improvements and efficiency gains throughout CSC'soperations.
“We began this project in 2005, completed everything by the startof 2007, and the benefits have been evident. Turnover rose from£4million to £8 million, and then to £15 million. This year, sectoranalysts are forecasting that we will hit £22 million,” says John.
“We have gained significant additional work with existingcustomers. As the oil and gas sectors have taken off, so our customershave grown, and we are now exporting more than 90% of our production.”
At the time of the MBO, the management team guaranteed 35 jobs,but the workforce is now running at just over twice that level.
For further information please contact Dr Ken Campbell at the CBM offices
on 0121 601 6350 or email [email protected]
Automotive supply chain techniquesworking wonders for Chesterfield
p r o f i l eC O M P A N Y
One of CBM's best-known members has been judged Ernst & Young'sManufacturing Entrepreneur of the Year, for the northern region.
www.chesterfieldcylinders.com
continued from page 13.... acceptance. Customers, particularly in theautomotive and defence industries have resisted material priceincreases since the beginning of demand resurgence and arestanding more firm in the recent period....a continuing challengefor all forgers caught between material suppliers and their end-usecustomers.
Scrap prices have jumped to record levels and exports from theU.S. continue strong to meet global and offshore demand,especially to India and China. Steel industry consolidation andrestructuring after a 10 year downturn led to a strong andcontinuing recovery since 2003. Both North American and globalcapacity have been added and are still coming on stream to serveglobal growth, but a lingering question remains as to how the steelindustry will handle a next turndown.
5. Industry ChallengesIt is clear that technical challenges dealing with materials, energy
and technology overlap with broader business issues involvinglabour, government, the environment, as well as marketing issues.Challenges in these areas require the industry to move beyondtechnical problems and deal with matters of education, perceptionand influence. Looking ahead, the industry must:
Improve its market positioning by pursuing a closerconnection to its customers; look for ways to collaborate withforging companies in other countries; and develop businesstools that help individual companies deal with marketinstability.Develop its current and future workforce by building betterrelationships with educational institutions; develop betterprograms to train workers; and improve recruiting efforts toboth attract and retain talent.
Establish industry guidelines and best practices byimplementing a world-wide data gathering of best practices;and further, to establish a common set of guidelines aroundforging operations and outputs.Advocate public policy agendas by implementing strongerand more targeted lobbying efforts and building politicalinfluence with public policy officials.Enhance material options and usage by developing betterways to minimize and process material waste in the forgingprocess; and work more collaboratively to enhance the rangeof material options available to the forging industry. Reduce energy costs and inefficiencies.Advance forging technology by pursuing greater automationof the forging process; develop new lubricants that canimprove die life; and generate innovations in the tools,equipment and process of forging.
A most significant challenge acknowledged in previous NorthAmerican industry reports was a need for the industry to abandona parochial view of the World, and be more global in its approach.That has happened at an increasing pace and trend since 2000.Exports are seen as helping the industry, even though thedomestic market is in slowdown.
Despite these challenges, the North American forging industrysees more and greater opportunities than ever before.
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Management and Labor has longed wanted to switch fromthe oils and wet lubricants to a more effective,environmentally safe, and “healthy” Dry Film Lubricant
for decades. There has been several introduced over the yearswith limited success. These different Dry Films were developedutilising the following technologies:
Soap based productsAnimal fat productsSingle Paraffin (polymer-type) products using solvents as the carrierHot Wax Melts
Because of the chemistry of these products, they were not as effective in thefollowing areas and did not impact the market very much at all. There were threedistinct areas of failure:
1. STAMPINGInability to do more than the most shallow of drawsInability to withstand multiple “hits”Inability to reduce incoming steel costsSome wash systems victimised due to the release of Paraffin'sBuild-up in the die after only a small number of partsAddition of an oil or wet lubricant to aid in forming on tough partsBlanks “sticking” together due to the Hygroscopic chemical nature of theseother DFL's, especially in humid weather
2. COATER/PROCESSORThe need for ovens up to 250 F to dry or “cure” the Dry FilmThe need to slow down the line speed to accomplish leveling and dryingThe need to heat some products to 180 F to prevent hardeningBecause many are hygroscopic (attracts water), and/or acidic in nature,rust would become a problem resulting in claimsBecause of being hygroscopic, when the coils are blanked, the blankswould tend to stick or “fuse” togetherThere would be build-up on rollers
All these problems have led to failures at the Customer's Press or frustrationat the Coater/Processor. This led to many 'Trials” that failed, and a bad taste inmany peoples' mouths.
3. HIGH COST OF COATINGIn addition, one of the main failures of Dry Films has been the cost of Coating.
The mid range gauges of Cold Roll, Stainless, Hot Dipped, Aluminum, have allbeen forced to the Painter/Coil Coaters. For these gauges - .015 - .070, thecoating has been done at these Painters with their Paint-Line Cost and Burdens,being added to the Coating Cost.
Thus, the Cost of Coating Dry Films in these lines would be in the $5.00-$7.00/cwt. range for steel and higher for aluminum.
However, in the heavier gauge Hot Roll steel market, serviced by the Pickler &Oilers (P & O), their coating cost was nominal, in the $1.00/cwt. range. This wasdue to their ability to coat in-line immediately after pickling. However, the productswere limited to the soap-based products which again, required heating up to 180 F, and slowing down the line. Heat was also needed at times as well.
What would be the answer?
AMERIFORM®
WHY IS AMERIFORM DIFFERENT?AMERIFORM® was developed by an Ex-Big 3 Manager of Stamping &
Manufacturing. Tired by the problems lubricants caused (and using plasticgarbage bags to help the drawing), he took an early retirement and worked on the project for 5 years before hitting his break-through technology, which led to
2 Patents. The marketing of AMERIFORM® began in the early 1990's, with the first customer AC Delco, saving $15.6M with using it and changing theirprocesses. From there, the Company, Source 1 Metal Treatments, has led thecharge to the acceptance of a Dry Film in the market and has enjoyed solidrelations with a number of customers.
Why is it so different from the other products on the market? What are the patents for?
We will again look at the advantages for both the Stamper and theCoater/Processor.
But first, why is AMERIFORM® so different?
THE AMERIFORM® PATENTED DIFFERENCEThere are several very significant differences:
1. AMERIFORM® has a multitude of Polymers “linked” together. Today, thereare some Dry Films that will say they are “acrylic” (which basically means theyhave a Paraffin Polymer) or Polymer-based. These products all use a singlePolymer, usually in the Paraffin family. There are virtually thousands ofPolymers available; ranging from the low-end Paraffin to the higher-end Polymers found in AMERIFORM®. Our Patent was issued due to our ability to “link” more than one Polymer together. Chemically, beforeAMERIFORM®, this could not be done. The advantages to having theseHigh-End Polymers, with varying heat points is:
ADVANTAGES FOR THE STAMPER
Deep draws can be accomplished as the varying Heat Points allowfor the AMERIFORM® to act like an extension ladder going up thework piece during the forming process keeping a barrier alwaysthere, thus not allowing splits, tears, and especially galling, etc.There can be multiple “hits” taken. It has withstood up to 32 “hits”on a Progressive Die.Because of the forming ability, Customers are able to reduce thesteel drawing grades for cost savings. We have seen parts go from IF to Commercial, EDDQ to DQ, etc. For Stainless, we havebeen able to reduce the % of Nickel for major cost savings.We reduce “Thinning” by as much as 20%.We reduce the frictional heat of the forming process by almost 30%, thus allowing for much longer die life.AMERIFORM® can also be burned off in annealing ovens andbrazing processes completely without leaving ash or contaminants(burns off into Hydrogen, Carbon and Oxygen molecules) withoutany damage to the atmosphere.Wash costs are reduced as AMERIFORM® is washed as “inertparticulates” which do not re-emulsify in the wash bath, thusextending the bath's life by 2x - 6x. Wastewater plant costs are alsoreduced as only the detergent's alkalinity needs to be neutralised.For aluminum automotive heat shields, washing is eliminated
2. Another Patented Difference is that AMERIFORM® has as its' “carrier”water. There are no solvents (such as Propylene Glycol); hot wax melts, etc. in the product. Thus, when the coil is coated, the water is “flashed off” or evaporated, thus leaving only the AMERIFORM® on the steel.Therefore, there are many advantages.
ADVANTAGES FOR THE COATER/PROCESSOR
When the coil strip comes out of the washer, the PMT (Peak MetalTemperature) will be usually at a minimum of 150 F. Normally, this is hot enough to evaporate off the water. Therefore, after coating, theAMERIFORM® is dry within 20 or 30 feet, therefore, no ovensare needed.
THE HISTORYOF DRY FILMS BY: JOHN SPENCER
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.055 cold roll mowerdecks - AMERIFORM®
reduced splits from10% to below 1% andreduced steel fromEDDQ to DQ
FOR FURTHER INFORMATION:
SOURCE 1 Metal Treatments, L.L.C. Sales & Distribution Company for: Stork Technologies, L.L.C, 815 East Pointe, Pt. Huron, Michigan, USA Tel: 810-987-6685
Europe: John Neale Ltd, 25, Fairfield Road, Halesowen, West Midlands, B63 4PT. Tel:- +44 (0) 121 585 8793 www.johnnealeltd.co.uk [email protected]
.076 stainlesstransmission housing -AMERIFORM® reducednickel from 11.5% - 9%and eliminated washing
.090 hot rollcylinder -
AMERIFORM®eliminated washing
before weldingand was burned
off duringannealing
.050 6016 T4PD aluminum headliners -AMERIFORM® reduced splits from 10-25%to below 1%
.027 5052 aluminum heat shield - AMERIFORM®
reduced splits from 25% to 1%, doubled Parts/Minute and eliminated the wash so shields go from press to assembly
.118 hot roll mower deck -FUSIONBOND Pre-Paint made all
25 pts of Inspection, had 450 hours of salt spray
The AMERIFORM® is not hygroscopic; therefore, a “protective”coating of Polymers is left on the steel. We have never had a rustclaim from our coaters. In fact, after stamping, we have parts thathave gone a year, two years, etc. without rusting. We do not claimthis as being a Rust Preventative but the results are evident.Because of the leveling characteristics, and the ability to dry quickly, the line speed can be increased dramatically.We do not build up on rollersWhen the steel is blanked, there is no “sticking” or “fusing”. We stay clean and dry. We have several independent test reports of blanks in high humidity chambers without sticking or rust.
In 2005, we had s very reputable Processing Company, modify a Wash/Slit lineby adding a coater. During the “shake-out” period, and the actual marketing ofAMERIFORM®, the coating line was running smoothly. Basically, the PMT ofthe metal coming out of the Vortex Washer was in the 150-180 F range. Thisallowed the line to run at speeds up to 800 FPM with a good coating on the metaland the drying accomplished within 10-15 feet from the Coater.
The eventual plan was to be able to coat, and then slit, all in one operation, thusgiving customers a low-cost package for both operations saving in logistical and time costs. Unfortunately, this company sold out to another and that line was closed.
LOW COST PRODUCERAny potential Coil Coater Partner for AMERIFORM®, such as a Paint Line
or a potential new Line to be built, needs to look closely at their reduced costs:
Ability to turn off ovens or run at low idleAbility to run line at maximum speed
By looking hard at the above 2 reductions in costs, anywhere from $1.00-3.00/cwt. can be realised for the Coil Coater. It would advantageous for the Coil Coaterto reduce their coating costs to capture a higher share of the market, but also moreimportantly, take some of the cost reduction in increased profitability which wouldagain, help drive a move towards this market.
Looking at the coating costs on the market today, we see the following:
GAUGE OF METAL TYPE OF COATER AVERAGE COST/CWT.
.015 - .070 Paint Lines $4.00 - 7.00/cwt.
.070 - .250 Hot Roll ONLY Pickle Lines $0.75 - 1.50/cwt.
Many Coil Coaters would also have the slitting capabilities that manycustomers prefer as their metal can be coated and slit at one plant, thus saving on time, freight, etc.
We believe that a Coil Coater could charge, again depending on tonnage, at arate much more competitive than the others in the market today.
GAUGE OF METAL TYPE OF COATER AVERAGE COST/CWT.
.015 - .070 Paint Lines OLD COST $4.00 - 7.00/cwt.
.015 - .070 Paint Lines NEW COST $1.50 - $4.00/cwt.
NEW PRE-PAINTS/PRIMERSDue to customer demand, SOURCE 1 has recently introduced two new paints
to the market. In several markets (including appliance, office furniture, etc.) pre-paints or “weldable primers” have been sold for many years. Again, like the DryFilm Market history we discussed earlier, these products had several failure points:
Inability to draw the metal more than a shallow draw“weldable” sometimes was in name only, welding is an issue in manylittle salt spray protection (many customers demand either 90 hours, 144 hours, 240 hours, or 1,000 hours)
SOURCE 1 listened and went to work recently introducing two new Paints:FUSIONBOND and LUMINCOAT:
FUSIONBOND:We incorporated the Patented Forming Technology of AMERIFORM®
with a urethane paint which allows us to “stretch” the paint further than themetal. Now, our customers can do deeper draws than just an inch or two. We are able to provide 450 hours of salt spray protection (we are workingon raising this to 1,000 hours). This is almost 3 times higher than some of the other products.We are 100% conductive, so therefore, 100% weldable. Also, being100% conductive, then E-coat or Top Coats, can be painted directly overFUSIONBOND.Has passed all Impact Tests up to 250lbs.Available in only black or gray.
LUMINCOATHas the same forming capabilities as FUSIONBOND, but is an epoxy based product.300-400 hours of salt spray protection.Not weldable.Can be color-matched.
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Over 360 Delegates from more than 10 countriesincluding England, France, Germany, Japan,China, the Netherlands and throughout North
America visited Grand Rapids for the 16th InternationalCouncil of Sheet Metal Presswork Associations (ICOSPA),September 14-17, 2008.
The ICOSPA Congress was held in the United States for the firsttime in 15 years and marks nearly 50 years of internationalnetworking and relationship-building by members of theinternational metalforming community. Representing the CBMwere myself and Director General, John Houseman.
Against the background of great turmoil in financial markets; avery close Presidential election battle and the remnants ofHurricane Ike, our hosts U.S. sister organisation the PMA(Precision Metalforming Association) organised a truly outstandingevent. The Congress opened with an evening reception at theGrand Rapids Museum of Art, where delegates were able to renewfriendships forged at previous meetings as well as make newacquaintances with colleagues from other countries.
The Congress proper opened with a keynote speech from JohnSnow, former U.S. Treasury Secretary, who gave us an excellentinsight in the current crisis spreading from Wall Street to the rest ofthe world and offered his own view of the measures which need tobe taken to prevent a future repetition of these events.
Other presentations ranged in subject matter from the training ofyoung people for our industry to the problems associated withforming high strength materials.
One of the most insightful offerings came from Jack Perkowski,chairman of ASIMCO, the largest privately held automotive-partssupplier in China, on his experiences in establishing anddeveloping a truly global metal-forming business. All in all a veryinteresting and varied mix of papers were presented, which weexpect to be made available by the PMA on video in the nearfuture.
One of the most interesting papers presented by John Kennedy,President and CEO of Autocam Corp., described how he boughtthe company with sales of $8m in 1988 and turned it into a globalmanufacturer of automotive components with sales of $387m in2007. However, on his journey he had learned some seriouslessons from developing a global supplier to the automotiveindustry which he shared with the audience. His business strategyinvolved identifying the market leaders, developing long term
relationships and achieving a global foot print. From the verybeginning he set out to be the lowest cost manufacturer for anygiven product produced in the region that he was working, this didnot mean low cost compared with Western countries, but low costin the country where product was being produced. Hepassionately believed innovation was the key to growth anddemonstrated how constant innovation could produce significantincreases in margin, whilst reducing the costs.
On one component he demonstrated which was selling for $1the original margin was only $0.04, however in a seven year periodthe costs had been reduced to $0.43 and the margin increased to$0.25, giving a reduction on the part price from $1 to $68. It wasthese types of improvements that had driven the dramatic growthof the business.
Unfortunately, when diversifying into France he learned avaluable lesson that you must understand the local culture. Havinglost a significant order and attempting to rationalise he found thesocial costs in France were unique to that country and found thatlean and productivity improvements were extremely difficult toimplement. He considered there was no incentive to competewhen redundancy costs for individuals were up to two yearswages. Also the high wages in France were $40 per hour versus$7 per hour in Poland. Goods were free to flow from EasternEurope which made competing extremely difficult. Governmentpermission is required to implement redundancies and this maytake up to 2 years, labour therefore becomes a fixed cost.
However, manufacturing in China had been very profitable andhad been developed using a joint venture with a Chinese partner.This was considered to be the only real opportunity to start up inthis area of the world. However, 80% of Chinese companies stilloperate with a return on assets of less than 10% and 20% are stilllosing money. Nevertheless, the opportunities in China aresubstantial with over 400 million affluent Chinese who aspire tobuying many Western goods. The Beijing Olympics had been verysignificant in turning the focus onto the environmental issuesbesetting China at this time and they will prove to be a watershedin the green awareness of the Chinese people not fully appreciateduntil now.
The conclusion was that the manufacturing world should beconsidered as 'flat', not every business is threatened by low cost companies but every business must be alert to risks andunderstand their costs in every region, competitors can developover night and the 'China prices' will not be sustainable. If direct
ICOSPA CONGRESS 2008BY ALAN SHAW, CBM PRESIDENT
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continued from page 17.... and indirect plant labour is more than 15%you probably need to be in a low cost country and also be in theregion where the goods are delivered - if you don't your competitorwill. World class productivity must be the first driver and locationprobably the second.
Grand Rapids is known for its sophisticated charm andmidwestern U.S. friendliness, and is also in the heart of a vast manufacturing region. Eight outstanding metalforming
companies from thesurrounding area invitedus to tour their facilities,offering insights intotheir manufacturing ex-pertise. The highlightsfor most visitors werethe vast automotivestamping facilities atPridgeon & Clay Incwith Tri-axis presses upto 2600 Tonnes, in-cluding the coil feedingof stock material up to 13mm thick by 500mm wide. Pre-dominantly servicing theautomotive industry thecompany uses a fulltime workforce of 1150employees. Its GrandRapids facility offered afully serviced approachto design prototypingvalidation and man-ufacturing excellence.The tour featured many different pro-cesses including fineblanking and the heavy
gauged conventional stamping up to 16mm.
Another highlight of the event was the visit to Steelcase Inc, aglobal leader in office furniture manufacture since 1974, employing16,000 people worldwide and annual sales of $2.6bn. Havingstarted from humble beginnings making metal waste bins in theearly 1900s to prevent office fires they have grown to be themarket leader. Their recent strategy has been to reduce their globalfootprint and introduce the latest manufacturing technologies,having reduced their headcount from 28,000 employees to theircurrent 16,000 and improved productivity by a factor of three
times. The vision of office equipment was changing as more usersaround the world have daily access to the world wide web, the rateof web users at 306 million in 2000 to an estimated 3.5billion usersin 2015 would have a profound effect on the work environmentand consequent office equipment manufacturers.
The invite to the much smaller, but most impressive facilities ofTrans-Matic Inc, where some truly astounding feats of precision insmall deep drawn parts was extremely interesting. They specialisein deep drawn metal stampings, progressive die stampings andvalue added assembly solutions. Trans-Matic uses its deep drawcapabilities to serve the automotive industry in braking, fueldelivery, air bag and sensor markets. Its non-automotive deepdraw capabilities serve the lock hardware compressor andplumbing markets. The tour featured the deep draw stampingpresses, transfer presses up to 600 tonnes and value addedassembly business.
The tour of Haworth Office Furniture, a world leader in thedesign and manufacture of office furniture, including raised accessfloors and storage equipment, demonstrated a very user-focusedand environmentally responsible company to the extent of usingwood recovered from beneath the waters of the Great Lakes. Thetour featured roll forming of the storage equipment, fabrication,stamping, finishing and assembly operations.
Running in parallel to the main Congress events, were the“NextGen” meetings. Nextgen is an initiative taken by the PMA toencourage and nurture the next generation of leaders for themetalforming industry. Succession in our businesses is a commonproblem which needs addressing in all countries represented atICOSPA. The PMA activities in this area are very practical andforward-looking. The U.K. companies could become part of theNextGen programme if there is sufficient interest among membercompanies.
The proceedings ended with a magnificent farewell banquetheld at the Frederick Meier Gardens and Sculpture Park, leaving us all with very happy memories of Grand Rapids, many new ideasfor progressing our industry, and new friends from all around the world.
Alan ShawPresident
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SHAPING THE WORLD OF METALFORMINGSHAPING THE WORLD OF METALFORMING
Alan Shaw, CBM President
sheet metalw w w. b r i t i s h m e t a l f o r m i n g . c o m 19
Researchers at Imperial College London areworking on a new sheet forming technology forheat-treatable aluminium alloys which could lead
to improved formability and reduced springback for deep drawn and stretch formed parts.
The novel high-temperature method can be used with all heattreatable aluminium grades and combines hot forming andquenching processes into a single operation. For solutionhardening grades, such as the 5xxx series, the resulting partneeds no further tempering and for age-hardening grades, suchas 2xxx, 6xxx and 7xxx, the part is in a state ready for aging.
The new process could be what is needed to reinvigorate theuptake of aluminium in the automotive sector, where thewidespread use has been hampered by the poor formability ofhigh strength aluminium grades, compared with currentdrawing steels.
Professor Lin, who invented the new technology withProfessor Dean while at the University of Birmingham, expectsaluminium and other light weight alloys to find increased usein the automotive sector. 'There is a global drive to producecars with lower emissions. One way to lower emissions is byreducing the car's weight. This is the driver for replacing steelwith aluminium,' he said.
The new system, dubbed by inventors Professors Jianguo Linand Trevor Dean as HFQ (Heat, Form-Quench), promises highformability, negligible springback and a short processing routewhen compared to traditional forming methods, yet it is notrestricted to the slow forming times seen in superplasticforming.
In the new process, the aluminium sheet blank is heated to itssolution heat treatment temperature of around 525°C. The hotblank is then transferred to a cold die set where it is quicklyformed and held within the dies until quenched to roomtemperature. The result is a fully formed part, with amicrostructure held in a solid solution phase. If an age-hardened grade is used, the part then can be aged to fullstrength.
Fifteen automotive manufacturers, component suppliers andexpert groups have joined an industry-lead consortium that hasbeen set up to steer the research. The consortium includesCBM, Lotus, Aston Martin, component manufacturers Wagon
Automotive, Lubricant specialists DA Stuarts and sheetaluminium producers Novelis. 'Companies are keen to see thistechnological development and want to be integral to thedevelopment from an early stage,' said Lin. The project ismanaged by Dr Alistair Foster, who works with PhD studentMohamed Mohamed to develop the technology.
'The forming process takes place at an elevated temperature,where ductility is far higher and springback is reduced becauseof the low yield point,' said Foster. 'The cold tooling rapidlyquenches the material, and because the part is held in place bythe tools, the quench does not cause the component to distort.'
The £488,396 EPSRC research grant, which was awarded toProfessor Jianguo Lin in 2007 to fund the development andproduce demonstration pieces, is now half way through its threeyear funding period. By the end of the project, Lin's teamhopes to have created a demonstration part, with a designsupplied by either Lotus or Aston Martin that was previouslyimpossible to produce in aluminium. 'Through hemisphericalpunch stretch forming tests, we have been able to show thatHFQ will considerably improve formability over traditionalcold forming in the T4 state' said Foster.
The use of age hardening aluminium grades requires anadditional process, whereby the part is held at a moderatetemperature for up to several hours to increase the strength.Automotive manufacturers would like the process to take placeduring the paint bake cycle, thereby removing the need for anadditional process. In the next stage of the work, the projectwill look to reduce the aging time to be compatible with astandard paint bake cycle.
Modelling tools will also be developed within the project toallow FE simulation of the forming process, optimisation ofproduction parameters such as the blank temperature andforming speed and for predicting the strength of the formedparts.
Also supporting this project are Innovel Technology, theInstitute of Sheet Metal Engineering, the AluminiumFederation, NAMTEC, Confederation of British Metalforming,Oerlikon-Balzers Coatings and Superform Aluminium.
For further information please contact Dr Alistair Foster at the Imperial College
on 020 7594 7130 or email [email protected]
The HFQ process has shown greater formability than standard cold formed T4 in a hemispherical punch test
Giving Aluminium the HOT-COLD TREATMENT
By
DR ALISTAIR
FosterIMPERIAL COLLEGE
FE simulation will be used to optimise the forming process and predict the strength of the part after quenching sh
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w w w. b r i t i s h m e t a l f o r m i n g . c o msteel20
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T he steel environment in early October is one of major andgrowing uncertainty. Industry executives, recently quizzed bySteel Business Briefing, believe European steel consumption in
2009 is unlikely to grow by more than 2-3% and that, in somecountries, consumption will actually decline. If there is growth, it willmost likely be in Scandinavia, Germany and Eastern Europe, they add.“What we need is confidence,” said one.
Many major mills around the world are either cutting production ormaking preparations to cut production in response to falling spot pricesand order shortages. The lack of credit is aggravating these negativetrends, and may well overtake the squashy steel market as the maincause of soft sentiment in the coming weeks, and maybe months.
To date, prices in general in northern Europe have held upreasonably well. They also seem likely to outpace those in southernEurope, which is traditionally more swayed by Chinese and otherimports. Germany in particularly, with its strong car and engineeringindustries has been a potent influence. However, as its exports dropped2.5% in August from a year ago, the sharpest fall since 2003; it isunclear for how long its industry will remain Europe's powerhouse. Ifthe Euro strengthens in the coming months, as many anticipate, thiswill speed hump the pace of exports of both steel products and steel-containing products to third countries.
But Steel Business Briefing believes prices have further to fall in thefinal quarter of this year and the early parts of the first quarter of 2009.The evaporation of the market froth that was generated in the springand early summer, on the back of the increases in raw material costs,has still to run its course.
However, the combination ofmill production curtailments, anda lowish level of imports shouldmean that north European spotprices will not fall to January2008 levels, as they may well doin many other parts of the world.The spot market price range forcommercial grade HRC in thefirst three months of 2009 is likelyto be in the range €600-650/t. Prices for contract sales for high qualitycoil products and plate should remain even firmer.
Distributors are working through the stocks they accumulated earlierin the year, and until these are run down, the market is unlikely to turnaround. Steel Business Briefing believes that for flat products, thisupswing could begin early in the 2009 first quarter and for longs a fewmonths later. The second quarter is usually construction's strongestseasonal period but, if the effects of the credit crunch continue, theupturn in prices could be delayed.
Most suppliers realise that sales will not increase if prices arereduced. Nevertheless, if import levels rise, then mills may have nooption, if they wish to move material, but to slowly pare prices. Chineseexports rose in summer 2008, and certainly some of that increase isdestined for Europe and North America. For the future, much dependson whether Chinese exports continue at a high level, whether the EastAsian economies return to their tigerish strength, and how muchChinese imports they absorb.
www.steelbb.com
U P D A T E
steelw w w. b r i t i s h m e t a l f o r m i n g . c o m 21
Over the past twenty years, the growth in the use ofstainless steel has been consistently higher thanother competing metals. This increased use has
been driven by economic growth and especially thegrowth in industrial and domestic consumption ofcountries like China, India and Brazil. However, thecompetitiveness of stainless steel compared with othermaterials was threatened in recent years by theextraordinary increase in the price of nickel whichpeaked at more than $50,000 per tonne in mid-2007.Whilst chromium is the vital ingredient of stainless steelwhich gives it its basic anti-corrosion property, nickelplays a key role as a provider of ductility, toughness andweldability. In fact the chrome-nickel austenitic stainlesssteels which typically contain 8-10% nickel (especiallytype 304 and 316) have been the workhorse gradessince the 1930s and by 2002 accounted for over 70% ofglobal production of stainless steel.
Although the price of nickel has reduced to c. $15,000 pertonne (in early October 2008), the extended period of relativelyhigh prices forced producers and users of stainless steel to explorealternative grades which contained no, or much less, nickel. Inparticular, the use of ferritic grades (i.e. the 400 series whichcontain no nickel) has been revisited. With greater availability, thedevelopment of grades with improved formability and therecognition of some over specifying in the past together withstrong promotion by the International Stainless Steel Forum (ISSF),there has been a renaissance in the use of ferritics during the pastfew years, such that their share of production has risen fromaround 22% in 2002 to 30% in 2007 and rising.
During the same period, growth in the use of another family ofgrades known as the 200 series has been seen also, with theirshare of world production growing from around 5% to over 10%.In these grades, some of the nickel is replaced by manganese butthey remain part of the austenitic group. Whilst their corrosionresistant properties are broadly equivalent to comparable chrome-nickel grades, the mechanical properties of the 200 series aredifferent and the range and availability of these grades remains limited.
Growth comparison with other metals
The BSSA is a trade association with morethan 100 member companies from all parts of the stainless steel supply chain and its purpose is to promote the increased use of stainless steel in the UK. The Association provides technicaladvice, training and education in all aspects ofstainless steel.
for stainless steelThe Outlook
Finally, there has been increased interest in the duplex typeswhich have a mixed austenitic-ferritic structure. They exhibit goodcorrosion resistance and generally have higher strength at ambienttemperatures than austenitic grades but are less formable andwhilst weldable, need more care. One of the best known is type2205 which has 5% nickel and a more recent development hasbeen the advent of lean-duplex grades such as 2101 and 2202which contain only 1-2% nickel.
Stainless steel really is a versatile material and this has helpedunderpin its market development. However, a note of caution!Changing the grade selection for any application should always bedone with care. Alternative types and grades may offer thepotential for lower input material costs but invariably meansdifferent processing parameters, mechanical properties andcorrosion resistance which may offset the initial savings. Alwaystake advice from your supplier and by all means consult theStainless Steel Advisory Service at the BSSA.
stee
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www.bssa.org.uk
Global production 2001-2007 with grade mix
by Nigel Ward, Director of the
British Stainless Steel Association
w w w. b r i t i s h m e t a l f o r m i n g . c o mcold rolled22
WORKING IN A CHANGING ECONOMYBy Erle Andrews, METSEC
www.crsauk.com
Collaboration with customers and suppliers to deliver a highlyfocused level of service offers the best route forward as theeconomy hovers on the cusp of recession, according to Metsec's
Managing Director, Erle Andrews (below).The Oldbury-based business is the UK's largest manufacturer of specialist cold
roll-formed products for the construction and manufacturing sectors, so hiscomment comes from a position of long-established commercial strength.
Metsec is also debt-free, and has enjoyed £35 million of investment during thelast decade, thanks to its quoted Austrian parent, voestalpine ag.
However, Erle remains a firm believer in the merits of corporate collaboration,especially via the CBM's Cold-Rolled Sections Association.
“There will always be aspects of each individual business which arecommercially sensitive, and must remain confidential, but there is still significantscope for us all to work together, to exchange knowledge, and to share bestpractice,” he says.
“We can always learn from others, whether it is about different ways ofaddressing legislative changes, tackling new challenges of design, or of sourcingnew materials.”
Metsec is currently focusing on reducing its carbon footprint - and its energybills - through a comprehensive sustainability programme.
“We've been working with advisers from the Carbon Trust, since the ISO 14001standard was revised in 2004, to improve our energy efficiency, and that of oursuppliers,” says Erle.
“Already, we've reduced our CO2 emissions by 25%, our gas consumption isdown by 37%, and our use of electricity has fallen by 14%.”Insulation of Metsec'smanufacturing areas proved very effective, as did the installation of fast-actingroller doors in its warehouses.
“The use of loop sensors to close the shutters, activated either automatically orvia the fork-lift drivers, has made a huge difference to our energy consumption,and to the working environment here, and at our Coventry site,” admits Erle.
Market conditions remain tough, with year-on-year production volumescurrently down between 20% and 30%, across Metsec's different operationalsectors.
However, although overtime levels have inevitably been slashed, the businesshas maintained its training schemes; with 25 apprentices and 10 graduateengineers on its books and with further investment committed, long term growthand prosperity are secure.
www.metsec.com
‘ ’.....there is still significantscope for us all to worktogether, to exchangeknowledge, and to share best practice
p r o f i l eM E M B E R
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In the current economic crisis it would be easy to bescathing about the financial sector, pessimistic aboutthe future and sceptical about anyone who claims to
know what is happening or has a plan which can controlit. Being wise after the event will not help those who havelost their businesses or jobs. However, identifying thepieces which may be left once the mayhem subsidesand seeing how things may fit together could perhaps beuseful to survivors in rebuilding for the future.
The largest users of metalformed components are theautomotive industry. In 2007 its value was ~4% of world GDP andinvolved ~17% of all trade in manufactured goods. Production andsales of vehicles were 74.6 and 71.9 million respectively withroughly a one third share between, Europe, North America andAsia Pacific. Figure 1a shows the trends in vehicle manufacturefrom 1960 to 2005.
Figure 1a: Regional passenger car production - 1960 - 2005
Figure 1b: Regional commercial vehicle production 1960 - 2005
Figure 1c: Regional total vehicle production - 1960 - 2005
Figure 1d: Global vehicle production per year 1960 - 2005
In passenger cars, Europe has remained constant whilst thedecline in North American production has been mirrored by thegrowth in Asia Pacific. For commercial vehicles, Europeanproduction has steadily declined. However from 1995 NorthAmerica kicked upwards and Asia Pacific reversed. The increasein North American production can be attributed directly to itsintroduction of the larger vans/SUV type vehicles which to avoidthe CAFE regulations were classified as LCV's.
The decrease in Asia Pacific was due to the 1998/99 financialcrisis. Figure 1c shows the convergence of the three dominantregions whilst Figure 1d shows the total growth over the period.Two points in figure 1d invite comment, the first indicating thatextrapolation suggests vehicle growth will reach 100 millionvehicles per year around 2014 and the second, the fallout from the1970's oil crisis. When the figures for 2010 are available, it will beinteresting to see how significant an impact the current crisis willhave had and more importantly, how quickly it will recover.
It is the recovery of the automotive industry which is key tometalforming. Whilst vehicle variants and market segments havedramatically increased over recent years the dominant factor hasbeen the drive for scale of economy through standardisation ofplatforms, modules and parts. The effect of this has cascadedthroughout the supply chain leading to major reductions in thenumbers of suppliers and an equally dramatic rationalisation ofmaterials, equipment, tooling and other associated providers ofproduct and services without which there would be no automotiveindustry. Moreover, it is on behalf of the vehicle manufacturers thatthese associated suppliers often introduce the new technologiesand developments needed to achieve the safety efficiency andcost savings required for them to remain globally competitive.These new metalforming opportunities are made available to otherindustrial sectors and rolled out as product and/or processimprovements. So, after the current crisis passes what will theautomotive jigsaw be like?
Around 2000, the speculation was for the 11 or so globalautomotive players to reduce to around 8 by acquisition andmerger. Cash rich Ford were chasing BMW for their PAG, Daimler
continued on page 24....
METALFORMING:OUR FUTURE?
ByDr Peter Standring,
University of Nottingham
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continued from page 23.... acquired Chrysler and a big share ofMitsubishi, Renault rescued Nissan and GM acquired Daewoo andSaab as it hoovered up bankrupt and failing players. Not a singleChinese, Indian or Russian company could be seen on thehorizon. Fast forward only eight years and the changes have beendramatic. In the first week of October published figures revealedthat the combined value of: BMW, Daimler, Renault, Peugeot, Fiat,GM, Ford, Mitsubishi and Hyundai at ~ 82.6bn was less than thatof VW and Toyota at 94 and 92bn respectively. Indeed, after thefall in its share price, the capitalisation of GM at ~$3.2bn was lessthan that of Mattel the die cast maker of model cars at ~$5.1bn.The question which could be asked is what has brought this aboutin only eight years.
Quite clearly the changes in automotive industry fortunes cannot be laid at the door of any single issue. Like the financialinstitutions there were some very expensive strategic errors made.However, the underlying factors were, the virtual saturation of thetraditional markets in Europe, North America and Japan, togetherwith the opening up of manufacturing opportunities in low costcountries and their potential growth as new markets. It is worthnoting that the combined populations of EU countries plus NorthAmerica and Japan only just account for ~10% of the worldpopulation. Between them China and India have ~ 40% and over80% of people live in developing regions. Faced with these starkfacts, the intense competition within the industry coupled with thelegacy costs of employment in most industrialised countries,forced vehicle manufacturers to pursue new opportunities forproduction in developing countries as their strategy for futuresustainability and growth. Link this with the parallel and separatepolicies of the Chinese government to establish a significant and inthe future dominant global automotive industry and mattersbecome clear.
Since 2000, the global vehicle manufacturers have invested ahugely significant proportion of their financial, technical, andpersonnel resources in their Chinese joint venture operations. Onthe other hand, the Chinese government, through its variousbodies, have set in place a raft of policies and systems which havebeen designed to achieve rapid technology transfer of automotiveknowledge from the global players into their developing 'pillar'industry. For the cost of a 50% maximum share of a joint venturebusiness, the Chinese government have enabled the domestic JVpartners to acquire first hand knowledge of the global industry andto roll this out to their wholly owned domestic companies for rapidup take. As the number of non JV made vehicles increase in Chinaso the 50% foreign owned share as a proportion of the total willdecrease. However, the question faced by global vehiclemanufacturers at the outset of China's strategic policy was, “Canit afford not to be involved?” Given stagnation in almost alldeveloped markets and the potential growth of China alone, theanswer is self evident. At present China has ~15 vehicles per 1000head of population - in the USA it is 800 vehicles per 1000. Ifvehicle ownership in China were to reach 100 per 1000 populationthe market requirement would be for 42 million vehicles per year(and this would still be eight times lower than in the USA)! In short,it is the potential scale of the home markets which provide themost significant element in the future development of theautomotive industry. Because of the strategic actions of theChinese government they have taken the lead but the situation issimilar in both India and Russia.
Since all vehicle manufacturers (with the notable exception ofToyota) are constantly seeking to outsource parts and subassemblies, it follows that a significant proportion of all automotivemetalformed parts will be delivered by Tier One suppliers. This of
course does not necessarily mean they will make them. Figure 2shows the distribution and value in 2007 of the world's top 100automotive suppliers by value. The location of these, as might beexpected, is predominantly in Japan, the USA and Germany.
Figure 2: Location and value of the top 100 global automotive Tier One suppliers in 2007. Total value ~ 380bn (x109). Figures in brackets indicate number of companies [1]
What is particularly interesting is that:
only one company has no involvement in the North American marketonly three companies have no involvement in Europeonly six companies have no involvement in Asia Pacific
Clearly, the distribution of the players in Figure 2 highlights theglobal nature of the automotive supply chain and its focus onproducing very large numbers of relatively few products. What isalso obvious is the absence of any automotive supply companies(as yet) from the developing countries of China, India or Russia.However, and here lies the rub, what once required years ofdedication, development and growth to build up can today beacquired by a private equity group or sovereign wealth fund at thestroke of a pen. That Porsche will soon acquire full control over VW(the 55th largest vehicle maker taking over the 3rd) and theSchaeffler Group gaining Continental have simply illustrated to themarket what can be done. Looking at Figure 2 there are apparentlyno Chinese, Indian or Russian companies in the top 100 suppliersbut that does not mean they cannot have a share or controllinginterest. In the current economic climate buying technology, futureorders and a seat at the top table is very easy if the money isavailable and it is part of the business plan. Should this take place,then the tendency for newly acquired Tier One partners to sourcefrom those in developing countries they already know and dealwith would be financially sensible and technically a sound way toestablish a long term strategy. To compete in such an environmentsub tier ones would have to have niche products and capabilitiesin order to gain and maintain a market presence.
Given the across the board drop in new vehicle sales, the fall inthe value of assets on leased vehicles and the urgent need todevelop new environmentally efficient models, what emerges fromthe current crisis could be a very different industry to that whichwent before. Major bankruptcies or their threat could cause thefragmentation and realignment of some global brands. What couldemerge might be new, largely unknown names from developingcountries finding their place in the sun. This could occur across thesupply chain where the fall out from fragmenting networks providenew opportunities to pick up and reshape the pieces for newbusiness ventures.
continued on page 25
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Bodycote’s environmentally friendlycorrosion protection systems
BODYCOTE WOLVERHAMPTON was established in 1923 primarily as a subcontract Sherardizingprocesser taking in manufactured product and
protecting these products against corrosion in harshenvironments.
Since then the company has developed into one of the countriesleading metal finishing processors adding a range of corrosionprotective processes to enable choice for the benefit of customer.
These processes include
Sherardizing A thermal diffusion process involving the components beingheated at temperatures of 360 deg C to 400 deg C, in thepresence of Zinc powder forming a Zinc Iron alloy coating.
The Sherardized coating offers a long term sacrificial,damage resistant coating to EN ISO 13811 and B S 4921.
SheraplexA duplex coating system combining the properties of both Sherardizing and Organic coatings. Approved to W I S 4-52-03.
Developed for the Oil and Gas , Water industries offers a minimum of 1000 hrs salt spray to A S T M B117, it incorporates an addition the top layer provides aninsulating barrier against bi-metallic corrosion
Organic CoatingsDelta Protekt, Delta Seal, Magni 565, Xylan.These specialized organic film coatings applied by either Dip spin or Spray techniques supply thin film coatings (8 to 20 microns)
These coatings provide relatively thin coatings with high salt spray resistance, idea for small fasteners for theautomotive industry.Typically 12 micron coating give 720 hrs salt sprayresistance.
Mechanical PlatingThis process involves the impaction by glass beads of Zinc orZinc/ Tin or Zinc/Aluminium coatings to the surface of metalcomponents.
Eliminates Hydrogen embrittlement when treating hightensile steel components.Alloy deposits enhance salt spray results
Continual investment has enabled Bodycote to utilize the latesttechnology to grow the market for its range of coatings and has thecapacity necessary to accommodate the requirements of a massvolume producers requiring a sacrificial corrosion protection basedon Zinc in its various forms.
The development of our processes to meet the demands ofindustry and ever increasing legislative controls is ongoing, throughour research and development department.
Ancillary complimentary servicesA team of corrosion application engineers are on hand to offer
expert advice on all aspects of our corrosion protection services.
utilising our fully equipped metallurgical laboratory; supportservices including salt spray facilities, XRF measuring equipment and chemical laboratory evaluation department.
Industries servedConstruction, Oil & Gas, Water Industry, Railways, Wind Energy, Telecommunications, Automotive.
continued from page 24....
In the 1970's the Japanese broke the global vehicle mould byoffering low cost models with significantly better reliability andstandard features which on most cars by the time were optionalextras. OK, they were prone to early and sometimes dramaticcorrosion problems, but so were the home produced vehicles.Import tariffs caused the introduction of supply chain transplantswhich raised the quality and performance of the indigenousmanufacturers. The Japanese road map for success was clearlymarked and other countries have followed it with success. Thatthe same map will be followed in the future by new entrants fromChina, India and possibly Russia is almost inevitable. The universalrequirement for local content suggests that the developmentsbrought about by the Japanese model in the latter part of the 20thcentury will bring about similar local opportunities in the 21st. To be part of this companies must operate to global standards andhave the skill levels and equipment that global players are seeking.This will mean fully trained staff, lean operations and thecapabilities to communicate anywhere at any level to achieve ahighly responsive output. These abilities are what the bestcompanies today are striving for and therefore will be demandedfrom tomorrow's suppliers. The current crisis will produce asignificant slowdown in growth and demand but it could provideprecisely the breathing space and encouragement to build a brightnew future for tomorrow. This is the message which RDA's andother government bodies should be pushing as the antidote to the bank bailout of “toxic assets.” As has been said, bailout moneyis simply a tourniquet to stem the haemorrhaging of life blood butit will not cure the problem. What is required are equivalent fundsdesigned specifically to help the automotive industry, establishtheir place in the 21st century expansion with metalformers at the forefront.
References
[1] Automotive News Europe 2008 Global Market Data Book, pub Crain Communications GmbH.
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A D V E R T O R I A L
Rapid Prototypingwith the “Dieless”Machining SystemBy
Ian
StirlingUK MACHINE TOOLS LTD
The Dieless machine is based on the Incremental FormingConcept which gives a unique approach to Rapid Prototypeand small batch production work.
Where companies have high costs associated with tooling manufacture for theforming of thin sheet metal the Dieless machine will allow the creation of complexformed parts for actual production use or to prove the integrity and functionalityof the component shape required.
Forming flexibility extends to Concave, Convex, Folding and even Hemmingand Trimming of parts.
Programming of the machines is completed with software which will create theprogramme from existing Cad data.
Forming of Aluminium, Titanium, Mild Steel and even perforated metal meshcan take place in material up to 4mm thick depending on type.
With reductions in tooling costs reduced development time and no expensivehard tooling development or manufacture and then storage to contend with; thelonger forming time of the Dieless machine can be justified.
Digital data forming allows easy modification of parts being developed whilethe process is quiet and machines require a minimum of floor space.
The process is relatively straight forward the mathematical model of the part isconverted into a digital controlled movement using the Amino Forming System(AFS) CAM software, developed for the dieless system. This is then transferred to the machine's 3-axis digital control system. The flat sheet metal is locked intoposition on the supporting table and the tool moves along the 'y' and 'z' axes.
The table moves in the direction of the 'x' axis and is fitted with a supportingtable the pressure generated from the cylinders allows pre-tensioning to beapplied to the metal being formed, if needed. The tool moves on the sheet metalfollowing a two-dimensional course, with a pressing force and predefined levelsof movement which are incrementally created according to the geometry of theCAD model.
The Amino Corporation (Japan) patented the Dieless sheet forming system for incrementally forming a thin sheet into simple or complex three-dimensionalshapes. The Dieless machine is designed and built by the Amino Corporation andmarketed by its European agents UK machine Tools Ltd
Amino are also experts in other forming technologies such as Fluid Forming,Rolling Shear Machines and Progressive Bending Systems.
UK Machine Tools Ltd specialise in Robotised Press brake Cells and LargeTube Laser Systems.
Forming Solutions for the Sheet Metal Industry
www.ukmachinetools.co.uk
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w w w. b r i t i s h m e t a l f o r m i n g . c o m 27business strategy
P ricing decisions impactdirectly upon sales revenuesand profitability. Charge
too much and orders are lost,while charging too little erodesmargins and may give theimpression that offerings are oflow quality.
Obtaining and sustaining higherprices ought to be a top priority of entrepreneurs. Yet often theyagonize over perfecting what is sold and then take quick pricingdecisions based largely on guesswork.
So how should businesses setprices? Hitherto pricing has beenshrouded in mystery. Firms haveeither been reluctant to reveal theirapproaches or sensitive to the lack of rigour involved.
A research team led by the authorhas persuaded 73 companies toreveal their pricing strategies, tacticsand practices. The firms surveyedprovided data on 127 factors thatcould affect pricing decisions. Thefindings set out in the report 'Pricingfor Profit'* reveal that more effectivepricing could boost the profitabilityof many companies.
Comparing the companies thatare most successful at using pricingto achieve business objectives such as growing market share orimproving profitability (the leaders)with the least successful (thelaggards) reveals stark differencesbetween the two groups. For ex-ample, leaders make more use of all nine tools and techniquesexamined. Over twice as many make "very extensive" use ofcompetitor analysis. Leaders areahead by two to one or more in theiruse of break-even analysis, economicvalue analysis and price sensitivity measurement.
Leaders understand the strategic importance of pricingand are more attuned to factors such as perceived valuethat affect price sensitivity. Overall, sales management,marketing, sales force personnel and finance are thegroups most involved in pricing. However, leaders involvea wider range of departments in pricing decisions andmembers of the sales team play a more significant role.
Marketing and sales should contribute to pricing as theyought to be close to customers. But left to themselves theymay be tempted to 'buy' orders. Offering discounts may beregarded as a softer option than differentiating, tailoringand delivering extra value to justify a higher price.However, excessive discounting can reduce profitability.
The most successful companies rely upon evidencerather than hunch. Thus before pricing products as a linerather than individually they would calculate whether an increase in profit overall would exceed the costs ofimplementation and any reductions in profit onindividual products that might occur.
Leaders attempt to sell on value as opposed to price.They are more likely to segment a market-place and take a long-term view, for example using 'penetration pricing'to enter a new market. When laggards look ahead it isoften for defensive reasons, for example cutting price tohold onto market share.
The cost drivers of leaders and laggards are very different.Leaders are five times more likely to increase volume to
....continued on page 28 busi
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COLIN COULSON-THOMASreveals how some companiesmanage to charge higherprices for their products and services than others.
w w w. b r i t i s h m e t a l f o r m i n g . c o m28 business support
achieve economies of scale. In contrast, laggards are morelikely to reduce product costs to allow price cuts or specialdiscounts. Leaders are more realistic when allocating costsand more likely to understand the direct and indirect costsattributable to a particular product or service.
Overall leaders adopt a very different approach tobuilding their businesses. They focus on each marketsegment, differentiate their offerings, and look for ways ofincreasing quality and delivering improved customerservice. Investing in these areas allows them to build salesvolume, reduce unit costs and become more competitive.
Leaders keep their pricing structures simple andtransparent. Increasing an offering's economic value andthe extent to which it is unique or special enables them toprice for value. Differentiated, tailored and exclusiveofferings attract a premium.
Laggards put the most emphasis upon cost cutting, whileleaders strive to add value to their core offering, develop areputation for service and use pricing to build closerrelationships with strategic customers and key accounts.They are more willing to enter into partneringarrangements.
Pricing tactics should support business developmentstrategy. Thus prestige pricing can enhance perceived value.
Within the euro zone cross-border buying and Europe-wide purchasing are increasing the demand for Europeanprices. Companies can resist downward pressure by
Further InformationColin Coulson-Thomas has helped over 100 boards to buildbusinesses and reviewed the winning business practices ofover 100 companies. He can be contacted by telephone on: 01733 361 149; Email: [email protected] or viawww.colincoulson-thomas.com
* 'Pricing for Profit... the Critical Success Factors' by ColinCoulson-Thomas is published by Policy Publications at £99and can be ordered from www.policypublications.com
....continued from page 27 developing clear benefits in each market and segmentingcustomers into ring-fenced pan-European groups.
Too often pricing is handled in an ad hoc anduncoordinated way. A balance may have to be struckbetween the centralised response demanded by majorcustomers, and the decentralisation needed to respond tolocal market conditions.
Automating the more routine aspects of pricing canreduce the risk of errors and free up time for creatingbespoke responses. Smart firms monitor trends anddevelopments that may impact on prices. For example,they are alert to possible price hot spots that might triggerconsumer militancy.
Overall, leaders put greater effort into pricing. They usemore techniques and a wider range of sources of priceinformation. They keep their finger on the pulse ofcustomer, user and industry opinion, and review theirapproaches, strategies and tactics as situations andcircumstances change.
The Equality Bill will be introduced in this next Parliamentary session with a view to con-solidating all the various parts of discriminationlegislation which have been on the statute bookssince the 1970s. The Government will also take theopportunity to introduce some more legislationwhich will have an impact on businesses, both largeand small.
Having brought in discrimination law on grounds of agein the workplace in October 2006, the Bill will seek toextend the law on age discrimination to the provision ofgoods, facilities and services. This will not happenimmediately as there will be consultation on the wording ofthe legislation to provide justifiable differences in thetreatment of different age groups relevant to particularindustries such as insurance.
Another theme running through the new Bill is trans-parency on pay. The Government will make it unlawful foremployers to prevent their staff from disclosing their payrates to one another. The Bill will also force public bodiessuch as local authorities to produce reports on certainpotential areas of inequality such as pay, which in effect willmake their pay rates public. Private organisationscontracting with public bodies such as local councils mayin the future be obliged to produce this information as wellso it's worth keeping an eye on how the law is changing.
For further information please visit Croner's website:www.croner.co.uk
NEW CHANGES TODISCRIMINATIONLAW COMING INNEW CHANGES TODISCRIMINATIONLAW COMING IN
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w w w. b r i t i s h m e t a l f o r m i n g . c o m 29
fina
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finance
T he state of the UK economy at present is puttinggreat pressure on the management of businessesthereby leaving little time for planning for the future.
However in the current market conditions whatever yoursize it is even more important to focus on the strategy for your business.
Deciding on the next step can be very difficult particularly whenyou have the day job to do to ensure the business runs smoothly.A strategic options review may be the tool to help you decide onyour future strategy. This is a rigorous analysis of the businesswhich is likely to identify a number of areas where improvementscan boost the business today, as well as increase the longer termchances of a more profitable sale, if this is an option you areconsidering.
How do you undertake a strategic options review?The starting point for any review is defining what you want to
achieve. Businesses are unique, dynamic entities and cannot betreated to a one size fits all approach. Therefore, the specifics ofeach review undertaken should be different. However, they shouldall start from the same point, that it is a full analysis and under-standing of shareholders objectives.
These objectives are not always purely financial, there are manypersonal objectives that need to be understood and considered inorder to develop a forward plan.
From here the review should move onto an informationgathering stage. This must be both internally and externallyfocussed, identifying the key influence third parties (competitors,customers, suppliers and potential buyers) have on the “what,why, when and how” of realising value from a business.
In terms of output, a quality review will deliver an opinion of the“what, why, when and how” that best fits your objectives. Thisopinion will be based on detailed and rigorous analysis.
What does this mean in reality?At its simplest, a strategic options review will help an owner
decide whether the best option is to hold, invest and grow thebusiness for a future sale or to sell, fully or partially, in the shortterm.
Therefore, a review will produce a clear picture of the currentappetite of trade buyers and private equity investors for yourbusiness, and the value and deal structures achievable. It will alsoproduce a detailed financial returns analysis of the hold, invest andgrow alternative and of selling some of the equity (or partial sale) toa third party. This third party would typically be a private equityinvestor, however, constructing such deals with corporates canalso be achieved.
The preferred option, or in some cases, options then has adefined action plan drawn up to address the key issues from thereview and ensure delivery of shareholder objectives. For example,in a recent transaction the price was not the only consideration forthe shareholders. In this case, the right solution was a sale tomanagement as this satisfied all shareholder objectives; realisingcapital value; leaving the business in safe hands and allowing themanagement team to take the business to the next level.
Don't focus on internal issuesIn assessing options and timings, and then defining an action
plan, owners and advisors can often focus too much on internalfinancial detail, such as profit trend analysis and balance sheetstrength. However, it's the prevailing climate in the wider world interms of overall economy, future predictions for your market thatdetermines whether, and at what value, buyers buy. In addition thereview will highlight importance of building your externalawareness and the external profile of your business, in terms ofpress profile in trade and national press and other marketing
communications such as your website. Questions should beasked if you PR and website are giving a positive image of yourcompany, if not this needs to be addressed.
How can I use a strategic review?A review can deliver real value in a number of ways. It may
highlight the next likely buyer of their business and when theirappetite is at its highest. Such a situation may result in youpursuing a sale much earlier than you anticipated in order tomaximise the return for the shareholders. In a recent transactioninvolving a manufacturer, the shareholders were not wedded to animmediate sale of the business as there were areas they wanted tofocus on internally. However the strategic review highlighted therewere a number a trade buyers actively looking for a foothold in theirmarket and it was the right time to sell the business. Whilst therewere still areas the business wanted to address internally, whichultimately would have improved the bottom line profit, the businesshas now been sold to an overseas acquiror for a strategic pricethat far exceeded the shareholders expectations.
Many issues and questions coming out of a review will be of aninternal nature. These will range from management structure,operational facilities and systems to the more granular issues suchas property leases, employee contracts and environmentalpractices. Action may need to be taken to address any issues that are identified by the review before they impact on the value ofyour business.
ConclusionA strategic options review will ask a number of questions of a
business and its shareholders, and deliver a route map towardsrealising maximum value. It will help you make the right decision forboth you and your business going forward and the benefits youcan gain from such an exercise should not be underestimated.
www.catalystcf.co.uk
MAXIMISINGTHE VALUE OF YOURBUSINESS
MAXIMISINGTHE VALUE OF YOURBUSINESS
Richard Sanders, Partner, Catalyst Corporate Finance
Cutting Waste is essential
We are all feeling the pinch of tighter credit. Raw material costs arerising, customers want items in the shortest lead time possible ata moment's notice and, of course, our employees are worried for their future. Your business needs cash to
keep the business cycle going and yet lead times are getting longer and inventory is not going down. It is time to cutwaste and act now.
w w w. b r i t i s h m e t a l f o r m i n g . c o m
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Lean ThinkingMost organisations have heard of lean principles and many haveattempted to implement the tools with varying degrees of success.The “lean temple” shows several of the tools and all offer greatbenefits for any organisation determined to run the course andmake them work. They are far from new and success is down topassion and belief in the fact that waste exists in all businessesand reducing it is simply down to applying the right tools to theright priorities by correctly trained people. We all want the benefitsthat we know lean methods can give us. The question is how canwe get started and how can I run my business, juggle priorities,keep down-time to a minimum and pursue a lean journey all at thesame time?
We can helpThe CBM have joined forces with Lean Education andDevelopment Limited (LEAD) to offer a structured changeprogramme which aims to deliver focused lean training at a shop floor and supervisory level. The programmes are projectbased involving some theory coupled with hands-on shop floorexperience. It is about driving real business benefits.
Lean Education and Development specialise in the delivery ofContinuous Improvement (CI) training which is underpinned with aNVQ model. This gives the programme a structure but is flexibleenough to be customised to suit your needs. The NVQ not only
allows individuals on the programme to gain a qualification butprovides a significant grant, funded by the Learning and SkillsCouncil, to substantially reduce costs (part of the currentlyadvertised Train-to-gain programme). Depending on the priorqualifications of the learners, most programmes attract a fund of between 85% and 100% of project costs.
It can be daunting when contemplating a change programme butwith the funding available through train to gain, this takes awaymuch of the risk.
The NVQ (Business Improvement Techniques or PerformingManufacturing Operations) concentrates on the general workforceat levels 2 and 3. Known as the Kaizen Foundation, KaizenPractitioner and the Kaizen Leader Programmes they cover theusual topics as shown in the lean temple diagram above e.g.,Standard Operating Procedures, Visual Management, 5S andProcess Mapping but is now funded. NVQ models have moved on a long way since their inception and now involve a strongemphasis on applied learning, workshops and projects and notsimply on assessing existing skills. It is about driving enterprisebenefits. It applies to all employees at all levels including those thatwork in the office, support areas, warehouse, maintenance as wellas the shop floor.
Value and QualityThe fact that the programme is heavily funded should not takeaway the need for excellent quality of service, value to yourbusiness and the bottom line improvement. The programmes willbe focussed on areas of greatest need, will drive real keyperformance indicators and be implemented at a pace that suitsyour business. The programme will represent a commitment fromyou, not in cash but in time. It is therefore essential that there is afocus, an objective and real business benefits.
Next StepsIf you are interested in taking waste out of your business, reducinginventory or improving delivery performance as part of anextremely cost effective programme, then we would love to hearfrom you. We are confident that the synergy between CBM andLEAD will benefit members greatly and offer some real advantageto you and your business through these difficult times.
For further information please contact Max Jones,Director of LEAD on: 07714 670926 or email [email protected]
Surviving the Credit Crunch -The Lean Imperative
continued on page 31....
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trai
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D EAN GREENHOUSE has become the first UK
apprentice to qualify as a Power Press Technician
from a UK based press manufacture for at least the
last 10 years. Schuler Presses UK, the Walsall based subsidiary
of Schuler AG, the world's largest manufacturer of mechanical
and hydraulic power presses, decided 3 years ago to invest in
an apprentice scheme to protect the future of their highly skilled
business. The Managing Director of Schuler Presses UK, Paul
Nicholson, himself a product of an apprenticeship scheme, has
a firm belief in the values that a technical training brings. Thus
when the needs of the business were assessed and it was seen
that a potential hole existed in the future for skilled technicians
the search began for a suitable candidate for the position of
an apprentice. The first place that the job was advertised
was internally to see if any of the existing workforce, many
of which had children in the right age group, would like to see
their children move into an engineering based career. Mick
Greenhouse, employed within the company under its many
guises (Wilkins & Mitchell, Verson Wilkins, Clearing International,
Muller Weingarten) for nearly forty years, proposed his son
Dean. Dean who had the previous summer already worked at
the company under a work-experience scheme was inter-
viewed and in September 2005 started his exciting new journey.
Dean started his apprenticeship by attending the first yeartraining centre at Aldridge technical centre followed by two further years at the company finally completing all credits and tasks required and becoming a fully fledged Service Technician.
An exciting part of Dean's training was the opportunity to gain experience at some of the company's internationalaffiliates and customers.
Dean's first exposure to the travel aspect of becoming a service technician was a visit to a sister company, BCNTechnical Services in Hastings, Michigan, USA. At just eighteenyears old, Dean was despatched to the USA via Manchester,Chicago and Grand Rapids airports, a journey which in itselfwas daunting enough for a young man alone. Once at the facilityin Hastings, Dean was asked to accompany an Americantechnician on a service call in Tennessee, one of the SouthernStates of America. This call involved a thirteen hour “road-trip”across 4 different states during which Dean was encouraged topurchase a souvenir from each state. He even got to drive ahuge American 5.7 litre. Pick-up truck (was he listening toCountry and Western music as well!).
Since leaving Dean has been to Sweden to install a new largepress crown and almost all automotive plants across the UK.
Quoting Paul Nicholson “we have been very pleased to watchDean flourish from a young schoolboy into a well respected,mature, likable and qualified member of our team”.
continued from page 30....
Max Jones is a Director of LEAD and an independent Lean Consultant.
Max has spent the last 11 years as the Operations Director for several leading organisations includingCaterpillar, Cookson Group and a small precision components manufacturing company. Prior tomoving into industry, Max was the General Manager for a Government backed lean consultancy andalso spent 5 years as a Project Manager for lean transformation with PricewaterhouseCoopers. Hehas also worked with the Warwick Manufacturing Group advising clients such as GKN Light Axles andAutomotive Products. Max has spent most of his career either running or advising companies that are undertaking business or supply chain lean transformation. A true lean thinker, Max has workedwith large and small companies to drive sustainable business benefits. Max has specific experienceof operations strategy and lean deployment, policy deployment, company-wide lean roll-out, cellularlayouts, single piece flow, kanban design, workplace organisation, team based kaizen, visualmanagement and workforce development programmes. Consultancy clients have included RaytheonCorporate Jets, British Aerospace Defence Dynamics, Bausch and Lomb Sunglasses, CaterpillarGroup and a local city council.
APPRENTICE PRESS TECHNICIAN QUALIFIES
Dean Greenhouse - at Schuler Presses UK
w w w. b r i t i s h m e t a l f o r m i n g . c o m32 health & safety
C ompanies in the sheet metal, forging or fastenermanufacturing sectors will all need to take someaction to comply with the REACH directive. But
you will not need to register anything, unless you are the sole European importer of a non-EU manufacturedsubstance, or unless the materials you are using containany substance of very high concern (SVHC), both of whichare quite unlikely.
For the vast majority of metal forming companies, the expectedactions are as follows:
1. Make a written assessment of the materials used in yourmanufacturing process. CBM can provide a template fordoing this. File this so it can be shown to the relevant REACHenforcement authority when requested in the future.
2. Contact the suppliers of the substances and preparations youuse in your manufacturing process to confirm that they will be pre-registered before the end of November 2008, in orderto be assured of continuity of supply. Do this in written form
so that you can include it in your file. At the same time, getconfirmation that the materials do not contain any SVHCs.CBM can provide an appropriate form letter.
3. Respond to any letter from your customers confirming thatyou are aware of the requirements of the REACH directive,and are taking the appropriate actions to comply, as in steps1 and 2 above.
The most important thing is to ensure that you will have writtenevidence that you have completed the actions required to fulfil yourresponsibilities. And also important is that you need to do items 1 and 2 quickly, because the period for your suppliers to pre-register ends on 30th November 2008.
heal
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WHAT YOUHAVE TO DOTO COMPLYWITH REACHREGULATIONS
For further information please contact
DR JOHN NEWNHAM at the CBM offices on 0121 601 6350
or email: [email protected]
CBM MEMBERSWHAT YOU
HAVE TO DOTO COMPLYWITH REACHREGULATIONS
R ehabilitation is a term that describes the activity ofclinical and vocational oriented care, which assists an individual to recover after illness or injury. The term
is used in the context of ensuring that the individual receivesthe appropriate medical assistance, while also taking steps toensure that employment matters are considered, to helpindividuals return to suitable working duties.
All CBM Members have this cover within the EmployersLiability Insurance section of their policy regardless of liability.
BUT HOW DOES IT WORK?Once insurers are notified about a work related accident or
illness, and with the consent of the patient and client, the case is reviewed by their claims team. The NHS may be providingadequate care so we monitor the patient's treatment and recoveryto ensure that this continues. However, Insurers are keen to ensurethat long waiting lists or other delays do not delay the individual'srecovery, so they may assist by organising private treatment toaccelerate the recovery process. When the right stage in therecovery process has been reached, insurers work with the injuredperson and employers to help them back into employment.
THE BENEFITS:1. The sick and injured, benefit from early co-ordinated healthcare
and a supportive process built round case management (ratherthan an adversarial one driven by litigation)
2. The employer has a rehabilitated employee back at worksooner, and a reduction in the hidden and direct costs ofabsence through injury and illness
3. Insurers benefit through reduced loss of earnings claims andreduced legal costs which benefit clients when negotiatingrenewal premiums.
insurancew w w. b r i t i s h m e t a l f o r m i n g . c o m 33
FOR FURTHER INFORMATION PLEASE CONTACT RICHARD GIBSON AT TOWERGATE LEICESTER
ON 0116 240 5325.
www.towergaterisksolutions.co.uk
Specialist Insurance for the Metalforming IndustryThe CBM Insurance facility administered by Towergate Risk Solutions Leicester is a bespoke Insurance package designed for its members. It provides innovative product design not available with most insurers, and is designed to keep insurance premiums consistent over a period of time.
Policy covers include
For further details on how this insurance facility can benefit your company or you would like a free impartial review of your present covers please contact:
Richard Gibson Towergate Risk Solutions – LeicesterTowergate House, 7 Dominus Way, Meridian Business Park, Leicester LE19 1RP
Tel: 0116 2405325 Fax: 0116 2405400Email: [email protected]
The Confederation of British Metalformers is an Introducer Appointed Representative of Towergate Risk Solutions.Towergate Risk Solutions and Towergate Risk Solutions Leicester are trading names of Towergate Underwriting Group Ltd.Registered Office: Towergate House, 2 County Gate, Stacey St, Maidstone, Kent, ME14 1STRegistered in England no. 4043759Authorised and regulated by the Financial Services Authority
• Employers Liability with FREE Incident Reporting Medical andRehabilitation
• Third Party Liability including Product Recall Cover up to £50,000• FREE Crisis Containment Cover up to £100,000
• FREE Health and Safety Loss Control Service• FREE Serious Accident Response Service • All Risks Protection of your premises including Molten Metal
Breakout Cover
insu
ranc
e
MEDICAL & VOCATIONALREHABILITATION COVERwith the CBM Insurance Facility
BY: RICHARD GIBSON, TOWERGATE
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W orking with some financial experts CBM ran an event on 9th October exploring the keyissues of buying and selling companies. This
event drew delegates from diverse businesses andprovided a clear insight on the processes and criticaldocuments.
O n 21st October the “Metallurgy for non-Metallurgists” event was attended by morethan 40 people. Heat treatment was amongst the
topics covered, and has been proposed as a further event.
O n 26th November CBM will run the “Heat treatment” event, providing greaterdetail and answering the questions raised on
21st October.
O n the 6th November there will be a“Highstrength steel” event probing the areas ofSpecification, Simulation, and Application. The
December event will be addressing the difficulty ofbidding for work on the 2012 Olympics.
If you have any suggestions for other events you would like us to convene please [email protected]
CBM are trying to provide a balancedprogramme serving the specific requirementsof the three sectors and addressing some of thebroader issues.
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a d d r e s s l i s t i n g f u l l m e m b e r s
A.M.C. UK Fasteners Ltd : 01536 271 920Units 3 & 4, Darwin Road, : 01536 271 929Corby, Northamptonshire NN17 5XZ www.amcukfasteners.co.uk
Alcoa Fastening Systems : 01952 290011Unit C Stafford Park 7, : 01952 290459Telford, Shropshire TF3 3BQ www.huck.co.uk
Avdel UK Ltd : 01925 811 243Hardwick Grange, Woolston, : 01925 856 491Warrington, Cheshire WA1 4RF www.acument.com
Avdel UK Ltd : 01707 292 093Pacific House, 2 Swift Fields, Watermead Ind Estate, : 01707 292 196Welwyn Garden City, Hertfordshire AL7 1LY www.acument.com
Barton Cold-Form Ltd : 01905 772 021Pointon Way, Stonebridge Cross Business Park, : 01905 777 041Droitwich Spa, Worcestershire WR9 0LP www.coldform.it
Caparo Atlas Fastenings Ltd : 0121 224 2000P O Box No 6, Heath Road, : 0121 224 2001Darlaston, West Midlands WS10 8UL www.atlasfastenings.com
Clevedon Fasteners : 0121 378 061911 Reddicap Trading Estate, Sutton Coldfield, : 0121 378 3186West Midlands B75 7DG www.clevedon-fasteners.co.uk
Clyde Fasteners Ltd : 01355 225 451Hawbank Road, College Milton, : 01355 263 191East Kilbride, Lanarkshire G74 5ET www.clydefasteners.com
Cooper & Turner Ltd : 01142 560 057Sheffield Road, : 01142 445 529Sheffield, Yorkshire S9 1RS www.cooperandturner.com
Floform Ltd : 01938 551 712Henfaes Lane, Welshpool, : 01938 551 757Powys, Wales SY21 7BJ www.floform.co.uk
Gesipa Blind Riveting Systems Ltd : 01535 212 200Dalton Lane, Keighley, : 01535 212 232West Yorkshire BD21 4JU www.gesipa.com
Griff Chains Ltd : 01384 569 415Quarry Road, Dudley Wood, : 01384 410 580Dudley, West Midlands DY2 0ED www.griffchains.co.uk
Henrob Ltd : 01244 837 220Second Avenue, Zone 2, : 01244 837 222Deeside Industrial Park, Flintshire CH5 2NX www.henrob.com
KTS Wire Industries Ltd : 0113 253 2421Howley Park Road, : 0113 307 6868Morley, Yorkshire LS27 0BN www.ktswire.com
Linread Northbridge : 01527 525 719Crossgate Road, Park Farm, : 01527 526 881Redditch, Worcestershire B98 7TD www.mckechnieaerospace.com
Lonestar PRD Group Ltd : 01902 636 246Kennicott House, Well Lane, : 01902 605 759Wednesfield, West Midlands WV11 1XR www.prdholdings.com
PRD Fasteners Ltd : 01902 639 160Unit 10/15, Monmer Close, : 01902 639 153Willenhall, West Midlands WV13 1JR www.prdfasteners.co.uk
Rawlplug Ltd : 0141 638 7961Skibo Drive, Thornliebank Industial Estate, : 0141 638 7397Glasgow, Scotland G46 8JR www.rawlplug.co.uk
Smith Bullough : 01942 520 250Unit 2A, Swan Lane, Hindley Green, : 01942 520 251Wigan, Lancashire WN2 4HD www.smithbullough.com
SPS International Ltd : 00 353 6171 6560Shannon Industrial Estate, : 00 353 6171 6584Shannon, County Clare, Ireland www.spstech.com
SPS Technologies (T.J. Brooks Div.) : 0116 274 4980191 Barkby Road, : 0116 274 0243Leicester, Leicestershire LE4 9HX www.spstech.com
Tucker Fasteners Ltd : 0121 356 4811177 Walsall Road, Perry Barr, : 0121 356 1598Birmingham, West Midlands B42 1BP www.emhart.com
Vaughan Jones Socket Screws Ltd : 01937 843 298Unit 352, Thorp Arch Trading Estate, : 01937 843 501Wetherby, Yorkshire LS23 7BJ www.vaughanjones.co.uk
Fasteners
Forging
ACE Industries Ltd : 01902 606 685St. Anne's Road, : 01902 631 841Willenhall, West Midlands WV13 1EA www.forgings-uk.com
Bedford Steels : 01246 299 100Effingham Road, : 01246 290 354Sheffield, Yorkshire S4 7YS www.bedfordsteels.co.uk
Bharat Forge Scottish Stampings Ltd : 01292 267 971Neptune Works, East Park Road, : 01292 613 408Ayr, Scotland KA8 9HR www.bharatforge.com
Bifrangi UK Ltd : 01522 585 800P O Box 22, Tower Works, : 01522 529 116Lincoln, Lincolnshire LN2 5DT
Brockhouse Group Ltd : 0121 556 1241Howard Street, Hill Top, : 0121 502 3076West Bromwich, West Midlands B70 0SN www.brockhouse.co.uk
Cerro EMS Ltd : 01922 476 641Goscote Lane, : 01922 475 225Walsall, West Midlands WS3 1PF www.cerro-ems.com
Chapmans Agricultural Ltd : 0114 285 6000Club Mill Road, : 0114 285 6001Sheffield, Yorkshire S6 2FH www.chapmans-uk.com
Chesterfield Special Cylinders Ltd : 0114 242 7500Meadowhall Road, : 0114 242 7501Sheffield, Yorkshire S9 1BT www.chesterfieldcylinders.com
Clydesdale Forge Company : 01384 252 587Marriott Road, Netherton, : 01384 231 005Dudley, West Midlands DY2 0LA www.clydesdale-forge.co.uk
Cramlington Precision Forge Ltd : 01670 716 811Unit 8, Atley Way, Nelson Industrial Estate, : 01670 737 814Cramlington, Northumberland NE23 1WA www.cpfl-tvs.com
Doncasters Blaenavon Ltd : 01495 790 345Forge Side, Blaenavon, Pontypool,Gwent, Wales NP4 9XG www.doncasters.com
Doncasters Precision Forgings Ltd : 0114 285 8100P O Box No 66, Penistone Road, : 0114 233 4860Sheffield, Yorkshire S6 2FR www.doncasters.com
Firth Rixson Forgings Ltd : 0114 219 3740Meadowhall Road, Wincobank, : 0114 219 1515Sheffield, Yorkshire S9 1HD www.firthrixson.com
Firth Rixson Forgings Ltd : 0114 219 3694Darley Dale, Matlock, Derbyshire DE4 2JB www.firthrixson.com
Firth Rixson Ltd : 0114 219 3000Firth House, P O Box 644, Meadowhall Road, : 0114 219 1111Sheffield, Yorkshire S9 1JD www.firthrixson.com
Footprint Tools Ltd : 0114 232 7080Admiral Works, Sedgley Road, : 0114 232 7089Sheffield, Yorkshire S6 2AH www.footprint-tools.co.uk
George Dyke Ltd : 01902 366 36529 Doctor's Piece, : 01902 637 238Willenhall, West Midlands WV13 1QB www.george-dyke.co.uk
GKN Driveline Birmingham Ltd : 0121 377 7000- Hamstead Plant : 0121 358 4033Old Walsall Road, Great Barr,Birmingham, West Midlands B42 1DZ
Heartlands Extrusion Forge Ltd : 0121 359 6861Rocky Lane, Nechells, : 0121 359 2972Birmingham, West Midlands B7 5EU www.hef.co.uk
Helipebs Ltd : 01452 423 201Sisson Road, Gloucester, : 01452 307 665Gloucestershire GL2 0RE www.helipebs.co.uk
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Sheet Metal
AGA Consumer Products Ltd : 01926 457 400T/A Rangemaster, Clarence Street, : 01926 457 658Royal Leamington Spa, Warwickshire CV31 2AD www.rangemaster.co.uk
Baylis Automotive (Smethwick) : 0121 500 4200Units 10 - 13, Spring Road, : 0121 500 6158Smethwick, West Midlands B66 1PF www.baylisautomotiveuk.co.uk
Berck Ltd : 0121 553 2726Titan Works, Pleasant Street, : 0121 553 1087West Bromwich, West Midlands B70 7DP www.bercklimited.co.uk
Calsonic Pressings Ltd : 0191 417 0084Unit 6, Bentall Business Park, Glover, District 11, : 0191 417 0184Washington, Tyne & Wear NE37 2PA www.calsonic.eu.com
Carlton Laser Services Ltd : 0116 233 9990470 Thurmaston Boulevard, Troon Industrial Estate, : 0116 233 9992Leicester, Leicestershire LE4 9LN www.carltonlaser.co.uk
Cirteq Ltd : 01535 633 333Hayfield, Colne Road, Glusburn, : 01535 632 966Keighley, West Yorkshire BD20 8QP www.cirteq.com
Cooper B-Line : 01278 783 371Warlow, Highbridge, : 01278 789 037Somerset TA9 4AQ www.cooperbline.co.uk
Cooper Crouse-Hinds (UK) Ltd : 01795 889 146Dorset Road, Sheerness, : 01795 889 127Kent ME12 1LP www.enclosures-crouse-hinds.uk.com
Henry Williams Ltd : 01325 462 722Dodsworth Street, : 01325 381 744Darlington, Co. Durham DL1 2NJ www.hwilliams.co.uk
Independent Forgings & Alloys Ltd : 0114 234 3000Victoria Forge, Livesey Street, : 0114 234 0261Sheffield, Yorkshire S6 2BL www.forgedinsheffield.com
Integriti : 0191 263 868639 Manor Road, Brampton Bierlow, : 0191 262 6428Rotherham, Yorkshire S63 6BJ www.integriti.co.uk
Kimber Drop Forgings Ltd : 01384 414 500Gawne Lane Works, Gawne Lane, Old Hill, : 01384 414 510Cradley Heath, West Midlands B64 5QZ
Koyo Bearings (Europe) Ltd : 01226 733 200P O Box 101, Elmihurst Lane, Dodworth, : 01226 204 029Barnsley, Yorkshire S75 3TA
Mettis Aerospace Ltd : 01527 406 400Windsor Road, : 01527 608 18Redditch, Worcestershire B97 6EF www.mettis-aerospace.com
Miking Ltd : 0191 415 5919Bentall Business Park, Glover, District 11, : 0191 415 1300Washington, Newcastle-upon-Tyne, Tyne & Wear NE37 3JD
Mills Forgings Ltd : 024 7622 4985Charterhouse Road, : 024 7652 5453Coventry, Warwickshire CV1 2BJ www.millsforgings.co.uk
MSI-Forging Division : 01302 366 961Carr Hill, Blaby, : 01302 340 663Doncaster, Yorkshire DN4 8DH www.msi-forge.com
Musashi Autoparts UK Ltd : 01443 866 1406 Hawtin Park, Gellihaf, Pontllanfraith, : 01443 812 570Blackwood, Gwent NP12 2EU www.musashi.co.jp
Padley & Venables Ltd : 01246 299 100Callywhite Lane, Dronfield, : 01246 290 354Nr Sheffield, Yorkshire S18 2XT www.padley-venables.com
Pandrol UK Ltd : 01909 476 101Gateford Road, : 01909 530 281Worksop, Nottinghamshire S81 7AX www.pandroluk.com
Parker Hannifin Ltd : 0121 550 6397Building 1, Belfont Ind. Estate, Mucklow Hill, : 0121 585 5300Halesowen, West Midlands B62 8DR
Premier Stampings Ltd : 01384 353 100Station Street, Cradley Heath, : 01384 353 101West Midlands B64 6AJ www.premierstampings.co.uk
Rollins Bulldog Tools : 01942 244 281Clarington Forge, Darlington Street East, : 01942 824 316Wigan, Lancashire WN1 3DD www.bulldogtools.co.uk
Schaeffler (UK) Ltd : 01554 747 748Bynea, Llanelli, : 01554 771 201Carmarthenshire S14 9TG www.schaeffler.co.uk
Shakespeare Forgings Ltd : 01384 632 420Macarthur Road, Cradley Heath, : 01384 632 429West Midlands B64 7RO
Smethwick Drop Forge Kidderminster : 01562 823 451P O Box 19, Kidderminster, : 01562 754 336Worcestershire DY11 7QE
Solid Stampings Ltd : 01384 636 421Portersfield Road, : 01384 639 163Cradley Heath, West Midlands B64 7BL www.solidswivel.co.uk
Somers Forge Ltd : 0121 585 5959Haywood Forge, Prospect Road, : 0121 585 6699Halesowen, West Midlands B62 8DZ www.somersforge.com
South Wales Forgemasters : 029 2081 0341Garth Works, Taffs Well, : 029 2081 0108Cardiff, Wales CF15 7YF www.swforgemasters.co.uk
Special Forged Products : 0114 2560 914Birch Road, : 0114 2560 053Sheffield, Yorkshire S9 3XL www.specialforgedproducts.com
Spromak Ltd : 0151 480 059211g Wilson Road, Huyton Business Park, : 0151 480 0656Merseyside L36 6AN www.spromak.co.uk
Stokes Forgings Dudley Ltd : 01384 342 550P O Box 18, Cochrane Road, Holly Hall, : 01384 342 551Dudley, West Midlands DY2 0SE
Stokes Forgings Ltd : 01922 704 800Victor Works, Northcote Street, : 01922 704 804Walsall, West Midlands WS2 8BH www.stokesforgings.com
T W Stamping Ltd : 0121 622 2600112-117 Charles Henry Street, Digbeth, : 0121 622 2700Birmingham, West Midlands B12 0SJ www.twstamping.co.uk
Thornton Precision Components Ltd : 0114 285 5881Lowther Road, Owlerton, : 0114 233 6978Sheffield, Yorkshire S6 2DR www.tpcl.com
Tinsley Bridge Ltd : 0114 2211 111Tinsley Park Spring Works, P O Box 89, : 0114 243 1331Sheffield, Yorkshire S9 2DZ www.tinsleybridge.co.uk
Turton Springs Ltd : 0114 270 1577Burton Road, : 0114 275 6947Sheffield, Yorkshire S3 8DA www.turtonsprings.com
Victoria Drop Forgings Co. Ltd : 01902 605 141Off Park Road, Wednesfield Road, : 01902 609 587Willenhall, West Midlands WV13 1AG www.victoriaforgings.co.uk
VTL Automotive Ltd : 01422 882 561Calderside Works, Luddendenfoot, : 01422 888 830Halifax, West Yorkshire HX2 6EL
W & P Forgings : 01482 323 08911 Hedon Road, : 01482 324 735Hull, Yorkshire HU9 1LL www.wp-forging.co.uk
W. H. Tildesley Ltd : 01902 366 440Clifford Works, Bow Street, : 01902 366 216Willenhall, West Midlands WV13 2AN www.whtildesley.com
William King Ltd : 0121 500 4121Union Road, : 0121 500 0421West Bromwich, West Midlands B70 9DR
Wyman Gordon Lincoln Ltd : 01522 525 492P O Box 590, Waterside North, : 01522 521 701Lincoln, Lincolnshire LN2 5XY www.wyman-gordon.com
Wyman Gordon Ltd : 01506 446 200Houstoun Road, Livingston, : 01506 446 300West Lothian, Scotland EH54 5BZ www.wyman-gordon.com
Yorkshire Fittings Ltd : 0113 270 1104Haigh Park Road, Stourton, : 0113 272 5299Leeds, Yorkshire LS10 1RT www.yorkshirefittings.co.uk
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Cooper Lighting and Safety : 01302 321 541Wheatley Hall Road, : 01302 303 220Doncaster, South Yorkshire DN2 4NB www.cooperindustries.com
Covpress Holdings : 024 7669 1000Burnsall Road, Canley, : 024 7667 8425Coventry, Warwickshire CV5 6RT www.covpress.com
Doncasters Bramah : 0114 251 2102Holbrook Works, Station Road, Halfway, : 0114 2474105Sheffield, Yorkshire S20 3GB www.doncasters.com
Durham Duplex : 0114 243 2313312/314 Petre Street, : 0114 244 4329Sheffield, Yorkshire S4 8LT www.durham-duplex.co.uk
Eu-Matic Div. of Multimatic Ltd : 024 7667 3333Herald Avenue, Coventry Business Park, : 024 7667 3222Coventry, Warwickshire CV5 6UB www.multimatic.com
Evenwood Industries Ltd : 01388 832 556Evenwood, Bishop Auckland, : 01388 832 966County Durham DL14 9NJ www.evenwood.co.uk
Falcon Foodservice Equipment : 01786 455 203Wallace View, Stirling, : 01786 469 454Scotland FK9 5PY www.falconfoodservice.com
Ford Component Manufacturing Ltd : 0191 428 6600Tyne Dock, South Shields, : 0191 428 6620Tyne & Wear NE33 5ST www.fordcomps.co.uk
Fowlers of Bristol (Engineers) Ltd : 0117 942 256325a Bath Buildings, Montpelier, : 0117 942 4770Bristol, Avon BS6 5PT www.fowlers-eng.com
Frank Dudley Ltd : 0121 452 8500Unit 2, Wiggin Street, Ladywood, : 0121 452 8519Birmingham, West Midlands B16 0AH www.frankdudley.com
Futaba-Tenneco UK Ltd : 01282 433 171Liverpool Road, Rose Grove, : 01282 446 545Burnley, Lancashire BB12 6HJ
G W Waite Ltd : 01229 582 046North Lonsdale Road, : 01229 583 893Ulverston, Cumbria LA12 9DN www.gwwaite.co.uk
Genex UK Ltd : 01922 710 050Fryers Road, Leamore Business Park, : 01922 495 813Walsall, West Midlands WS2 7NA www.genexuk.co.uk
Glen Dimplex Home Appliances : 0870 444 9919Stoney Lane, Prescot, : 0870 458 9674Merseyside L35 2XW www.gdha.com
Grorud Group Ltd : 01207 590 471Castleside Industrial Estate, Castleside, : 01207 599 810Consett, County Durham DH8 8JA www.grorud.com
Grove Metal Sections Ltd : 01902 601 697Unit 7, Tractor Spares Industrial Estate, : 01902 603 279Strawberry Lane, Willenhall,Wolverhampton, West Midlands WV13 3RN www.grovems.com
Guala Closures UK Ltd : 0121 533 6288[GlobalCap Metal Closures Ltd], P O Box 32, : 0121 525 4636Bromford Lane, West Bromwich, West Midlands B70 7HY www.globalcap-group.co.uk
H V Wooding Ltd : 01303 264 471Range Road, Hythe, : 01303 262 408Kent CT21 6HG www.hvwooding.co.uk
Hadley Industries Plc : 0121 555 1300PO Box 92, Downing Street, Smethwick, : 0121 555 1301Warley, West Midlands B66 2PA www.hadleygroup.co.uk
Havelock Europa Plc : 01383 823 636Westway, Hillend Industrial Park, : 01383 824 749Dalgety Bay, Fife KY11 9HE www.havelockeuropa.com
Kiyokuni Europe Ltd : 01952 292 920Hollyhead Road, Priorslee, : 01952 292 940Telford, Shropshire TF2 9TY www.kiyokuni.co.uk
Krupp Camford Pressings Ltd : 01554 772 233Llethri Road, Felinfoel, : 01554 777 425Llanelli, Carmarthenshire SA14 8EU
Laser Process Ltd : 01543 495 000Upper Keys, Keys Park, : 01543 495 001Cannock, Staffordshire WS12 2GI www.laserprocess.co.uk
Leonardt Ltd : 01746 861 203Main Road, Highley, : 01746 862 296Bridgnorth, Shropshire WV16 6NN www.leonardt.com
Metsec Plc : 0121 601 6000Broadwell Road, Oldbury, : 0121 601 6123Warley, West Midlands B69 4HE www.metsec.com
Milton Keynes Pressings Ltd : 01908 271 94043a Barton Road, Water Eaton Ind Estate, : 01908 625 570Bletchley, Milton Keynes, Bedfordshire MK2 3EF www.mkp.co.uk
Northern Automotive Systems Ltd : 01873 832 263Ty Mawr Road, Gilwern, : 01873 832 034Abergavenny, Wales NP7 0EB
Pianoforte Supplies Ltd : 01604 862 441Simplex Works, Roade, : 01604 862 427Northampton, Northants NN7 2LG www.psluk.co.uk
Portola Packaging Ltd : 01302 552 4003 Carriage Drive, White Rose Way, : 01302 365 541Doncaster, Yorkshire DN4 5NT www.portola-europe.com
Pressed Metal Products Ltd : 0121 555 6061Unit 5 Heath Street Ind Estate, Abberley Street, : 0121 555 6058Smethwick, West Midlands B66 2QL www.pressed-metal.com
Presspart Manufacturing Ltd : 01254 584 126Whitebirk Industrial Estate, : 01254 584 100Blackburn, Lancashire BB1 5RF www.presspart.com
Rical Group : 01384 569 283Multiforms, Woods Lane, : 01384 633 712Cradley Heath, West Midlands B64 7AL www.ricalltd.com
Rical Group : 0121 555 4807Tramway, Oldbury Road, : 0121 555 4804Smethwick, West Midlands B66 1NY www.ricalltd.com
Rittal-CSM Ltd : 01752 207 600Broadley Industrial Estate, Roborough, : 01752 207 625Plymouth, Devon PL6 7EZ www.rittal-csm.co.uk
RSM Industries Ltd : 024 7636 2082School Lane, Exhall, : 024 7636 2434Coventry, West Midlands CV7 9NN www.rsmindustries.co.uk
Sertec Ltd : 01675 463 361Gorsey Lane, Station Rd. Industrial Estate, : 01675 465 539Coleshill, West Midlands B46 1JX www.sertec.co.uk
SPS Aerostructures Ltd : 0115 988 0185Willow Drive, Sherwood Business Park, Annesley, : 0115 988 0001Nottingham, Nottinghamshire NE15 0DP www.spstech.com
Stadco Castle Bromwich : 0121 382 3120Vantage Way, Erdington, : 0121 377 3698Birmingham, West Midlands B24 9GZ www.stadco.co.uk
Stadco Powys : 01691 648 561Llanfyllin, Powys, : 01691 648 836Wales SY22 5DH www.stadco.co.uk
Stadco Shrewsbury : 01743 462 227Harlescott Lane, : 01743 452 529Shrewsbury, Shropshire SY1 3AS www.stadco.co.uk
Steel Service Centre Ltd : 01889 270 241Hangar 5, New Road, Hixon, : 01889 270 242Stafford, Staffordshire ST18 0PJ www.steelservicecentre.co.uk
Swann-Morton Ltd : 0114 234 4231Owlerton Green, : 0114 231 4966Sheffield, Yorkshire S6 2BJ www.swann-morton.com
The Regent Engineering Co : 0121 526 6060(Walsall) Ltd : 0121 526 4789Salisbury Street, Darlaston, Wednesbury, West Midlands WS10 8XB www.regenteng.com
Thyssenkrupp Tallent Ltd : 01325 313 232Aycliffe Industrial Park, Newton Aycliffe, : 01325 311 473County Durham DL5 6EP
ThyssenKrupp Woodhead Ltd : 01132 441 202177 Kirkstall Road, : 01132 347 738Leeds, Yorkshire LS4 2AQ www.thyssenkrupp.com
TKA Body Stampings Ltd : 01543 466 664Wolverhampton Road, : 01543 466 665Cannock, Staffordshire WS11 1LY
TKA Bourn Plant : 01954 213 200Bourn Plant, Bourn Airfield, : 01954 213 369Bourn, Cambridgeshire CB3 7TQ
UYS Ltd : 01865 334 860Garsington Road, Cowley, : 08702 386 300Oxford, Oxon OX4 2BW www.uys.ltd.uk
Walsall Pressings Co Ltd : 01922 721 152Wednesbury Road, Walsall, : 01922 721 106West Midlands WS1 4JW www.walpres.co.uk
X-met Fabrication & Finishing Ltd : 01698 733 533Unit 106/107 Howden Avenue, : 01698 734 617New House Industrial Estate, Motherwell, Lanarkshire ML1 5RX
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Ajax Tocco International Ltd : 0121 322 80002 Dorset Road, Saltley Business Park, : 0121 322 8080Saltley, Birmingham, www.ajaxtocco.co.ukWest Midlands, B8 1BG ajaxtocco.com
Carrington Wire Ltd : 01422 372 372Carrington House, Lowfields Way,Lowfields Business Park, Elland, West Yorkshire, HX5 9DA www.carringtonwire.com
Corus Construction & Industrial : 01724 404 040Commercial Centre, P O Box 1, Brigg Road, : 01724 282 599Scunthorpe, Lincolnshire, DN16 1BP www.corusconstruction.com
Dorken MKS-Systeme GmbH & Co KG : 0121 745 895911 Arnold Grove, Shirley, : Solihull, West Midlands, B90 3JR www.doerken.de
Henkel Loctite Adhesives : 01629 824 17152 Cromford Road, Wirksworth, : 01629 822 578Derby, Derbyshire, DE4 4FR www.henkel.com
HHT (Midlands) Ltd : 0121 526 4771Heath Road, Darlaston, : 0121 526 4153West Midlands, WS10 8LU www.hht.co.uk
IRIS Business Solutions [Chorus] : 01274 851 577633 Halifax Road, Liversedge, : 01274 851 631West Yorkshire, WF15 8HG www.iris.co.uk
Johnson Machine & Tool Co Ltd : 0121 568 8013Mercury Works, Westbourne Road, : 0121 526 4984Darlaston, West Midlands, WS10 8BJ www.johnson-group.co.uk
National Machinery UK Ltd : 0121 585 98463rd Floor Trinity Point, New Road, : 0121 501 1936Halesowen, West Midlands, B63 3HY www.nationalmachinery.eu
Ovako Ltd : 0121 709 0110Unit 2, Britannia Park, Trident Drive, : 0121 709 0070Wednesbury, West Midlands, WS10 7XA www.ovako.com
The Bifurcated & : 01296 314 300Tubular Rivet Company : 01296 482 424A Division of Aylesbury Automation Ltd, Unit 2, Farmbrough Close, Stocklake Industrial Park,Aylesbury, Buckinghamshire, HP20 1DQ www.bifandtub.co.uk
Fasteners
Forging
Acheson Colloids Co : 01543 450 99047 Holly Road, Sidemoor, : 01543 450 299Bromsgrove, Worcestershire B61 8LG www.acheson.industries.com
Acheson Industries (Europe) Ltd : 01823 430 0346 Lydeard Mead, Bishops Lydeard, : 01823 430 034Taunton, Somerset TA4 3UD www.acheson.industries.com
Ajax Tocco International Ltd : 0121 322 80002 Dorset Road, Saltley Business Park, : 0121 322 8080Saltley, Birmingham, www.ajaxtocco.co.ukWest Midlands B8 1BG ajaxtocco.com
Bodycote Heat Treatments Ltd : 01625 505 300Springwood Court, Springwood Close, : 01625 505 312Tytherington Business Park, Macclesfield, Cheshire SK10 2XF www.bodycote.com
Chesterfield Special Steels : 01246 451 666Pottery Lane, Whittington Moor, : 01246 260 092Chesterfield, Derbyshire S41 9BH www.chesterfield-special-steels.co.uk
Corus Group : 01709 371 234P O Box No 50, Aldwarke Lane, : 01709 826 233Rotherham, Yorkshire S60 1DW www.corusgroup.com
DavyMarkham Ltd : 0114 291 4212Prince of Wales Road, Darnall, : 0114 244 9641Sheffield, Yorkshire S9 4EX www.davymarkham.com
Derek Johnson : 024 76411 2089 Delaware Road, : Coventry, Warwickshire CV3 6LY www.kespar.co.uk
Deritend Induction Services : 01922 621 664Robust Works, Rollingmill Street, : 01922 723 128Walsall, West Midlands WS2 9EN www.deritend.co.uk
Dielife Limited : 01642 221 13330 Commercial Street, , : 01642 245 171Middlesbrough, North Yorkshire TS2 1JW www.dielife.com
Euromarch Ltd : 01452 525 259Wil El Mil, 7 Ashville Road, : 01452 300 654Ashville Industrial Estate, Gloucester, Gloucestershire GL2 5EU
Fabreeka International Inc. : 01274 531 3338-12 Jubilee Way, Thackley Old Road, : 01274 531 717Shipley, West Yorkshire BD18 1QG www.fabreeka.com
Finkl UK : 0121 544 4506Langley Green Road, Langley, : 0121 544 4752Oldbury, West Midlands B69 4TR www.finkl.com
Forge Tech Services Ltd : 0161 339 1120Gatefield Works, Whitelands Road, : 0161 343 2257Ashton-under-Lyne, Lancashire OL6 6UG www.forgetechservices.com
Fuchs Lubritech (UK) Ltd : 020 8345 5566Eley Road, Eley Estate, : 020 8884 3255Edmonton, London N18 3DB www.kspaul.com
Lasco UK Agent : 01902 672 49120 Eversley Grove, Sedgley, West Midlands DY3 3RF
Micas Simulations Ltd : 01299 822 522P O Box 4190, : 01299 828 840Stourport-on-Severn,Worcestershire DY13 0WU www.micassimulations.co.uk
Newelco Division : 01633 263021of Inductoheat Europe Ltd : 01633 264 413Church Street, Newport, Gwent, Wales NP9 2TW www.newelco.co.uk
Oilgear Towler Ltd : 0113 394 7300Oaklands Road, Rodley, : 0113 255 9537Leeds, Yorkshire LS13 1LG www.oilgeartowler.co.uk
Pearson Panke Ltd : 020 8959 32321 - 3 Hale Grove Gardens, : 020 8959 5613London, Middlesex NW7 3LR www.pearsonpanke.co.uk
SMS Mevac UK Ltd : 01606 551 421Road 4, Winsford, : 01606 553 078Cheshire CW7 3RS
Strayfield Ltd : 0870 428 1086Ely Road, : 0870 428 1087Theale, Berkshire RG7 4BQ www.strayfield.co.uk
Timet UK Ltd : 0121 356 1155P O Box 704, Witton, : 0121 356 5413Birmingham, West Midlands B6 7UR www.timet.com
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Sheet Metal
DavyMarkham Ltd : 0114 291 4212Prince of Wales Road, Darnall, : 0114 244 9641Sheffield, Yorkshire S9 4EX www.davymarkham.com
Dorken MKS-Systeme GmbH & Co KG : 01299 271 451Pinkham Lane, Cleobury Mortimer, Shropshire DY14 8QF www.doerken.de
Institute of Sheet Metal Engineering : 01785 716 886P O Box 2242, Stafford, : 01785 716 886Staffordshire ST17 0WH www.isme.org.uk
Midlands Occupational Health Service : 0121 601 404183-87 Birmingham Road, : 0121 4042West Bromwich, West Midlands B70 6PX www.mohs.co.uk
Oerlikon Balzers Coating Ltd : 01908 377 277Bradbourne Drive, Tilbrook, : 01908 361 362Milton Keynes, Buckinghamshire MK7 8AT www.balzers.co.uk
Pearson Panke Ltd : 020 8959 32321 - 3 Hale Grove Gardens, : 020 8959 5613London, Middlesex NW7 3LR www.pearsonpanke.co.uk
Planit Software Ltd : 01225 721 330Limpley Mill, Lower Stoke, : 01225 721 333Limpley Stoke, Bath, Avon BA2 7FJ www.planit.com
Professional Polishing Services Ltd : 0121 555 656918B Parkrose Industrial Estate, : 0121 555 6613Middlemore Road, Smethwick, West Midlands B66 2DZ www.professionalpolishing.co.uk
Ross UK Ltd : 0121 559 4900Cakemore Road, Rowley Regis, : 0121 559 5309Warley, West Midlands B65 0QW
Royal Bank of Scotland : 0121 262 7409Invoice Finance, 3rd Floor : 0121 262 75452 St Phillips Place, Birmingham,West Midlands B3 2RB www.rbsif.co.uk
SEMTA : 01923 238 44114 Upton Road, Watford, : 01923 652 388Hertfordshire WD18 0JT www.semta.org.uk
TEK Personnel Consultants : 0114 252 5730Bells Square,Trippet Lane, : 0114 252 5731Sheffield, Yorkshire S1 2FY www.tekpersonnel.co.uk
The Bifurcated & : 01296 314 300Tubular Rivet Company : 01296 482 424A Division of Aylesbury Automation Ltd,Unit 2, Farmbrough Close, Stocklake Ind Park, Aylesbury, Buckinghamshire HP20 1DQ www.bifandtub.co.uk
Towergate Risk Solutions : 0116 240 5300Towergate House,7 Dominus Way, : 0116 240 5400Meridian Business Park, Leicester, Leicestershire LE19 1RP www.towergate.co.uk
TTI Group Ltd : 0121 327 2020PVD Coating Centre, Unit 4, Bickford Road, : 0121 327 6461Witton, Birmingham, West Midlands B6 7EE www.ttigroup.co.uk
Whiston Industries Ltd : 01384 560 606Oak Street, Cradley Heath, : 01384 638182West Midlands B64 5JY www.whistonindustries.com
Overseas
Bharat Forge Ltd : 00 91 212 671 666P O Box No 57, Pune Cantonment, : 00 91 212 56181Pune 411 001, Maharastra, India
China Forging Industry Association : 00 86 10 6846 5045Forging & Stamping Services Centre, : 00 86 10 6846 50445 Xisanhuan Beilu, 100081 Beijing, P.R. China
CPM : 00 49 2407 95940Kaiserstrabe 100, : 00 49 2407 9594 66D-52134 Herzogenrath, Germany
Ewald Dorken AG : 00 49 2330 630Wetterstrassse 58, : 00 49 2330 63354D - 58313 Herdecke, Germany www.doerken.de
Forging Industry Association : 00 1 216 781 6260Suite 300 - LTV, Landmark Office Towers, : 00 1 216 781 010225 Prospect Avenue West, Cleveland, Ohio 44115, USA
Japan Forging Industry Association : 00 81 3 3241 7661Nihonbashi-Kaishin-N.Y. Building, : 00 81 3 3241 76631-13-5 Nihonbashi-Muromachi, Chuo-ku, Tokyo, Japan103
Lasco Umformtechnik GmbH : 00 49 9561 6420Hahnweg 139, : 00 49 9561 642 333D-96450 Coburg, Germany www.lasco.com
Pietro Rimoldi & C SRL : 00 39 0 331 504 449Via Gerenzano No 44, : 00 39 0 331 504 325I21053 Castellanza, Varese, Italy
Presstrade GmbH : 01788 890 055Presstrade UK, c/o Lodge Consulting Ltd, : 01788 899 090Merryhill House, Braunston, Northamptonshire NN11 7HS www.presstrade.com
SMS Meer GmbH : 00 49 214 7340Josefstrasse 10, : 00 49 214 734 222D-513 77 Leverkusen, Germany www.sms-eumuco.de
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COMPANY TYPE WEB TEL
A.M.C. UK Fasteners Ltd ..............................................................................FM / ................................................www.amcukfasteners.co.uk ..........................................01536 271 920ACE Industries Ltd ............................................................................................FM / ................................................www.forgings-uk.com ....................................................01902 606 685Acheson Colloids Co ..........................................................................................AM / ................................................www.acheson.industries.com ......................................01543 450 990Acheson Industries (Europe) Ltd ..............................................................AM / ................................................www.acheson.industries.com ......................................01823 430 034AGA Consumer Products Ltd T/A Rangemaster ..........................FM / ................................................www.rangemaster.co.uk ................................................01926 457 400Ajax Tocco International Ltd ......................................................................AM / ................................................www.ajaxtocco.co.uk / ajaxtocco.com ......................0121 322 8000Ajax Tocco International Ltd ......................................................................AM / ................................................www.ajaxtocco.co.uk / ajaxtocco.com ......................0121 322 8000Alcoa Fastening Systems ................................................................................FM / ................................................www.huck.co.uk..................................................................01952 290011Avdel UK Ltd..........................................................................................................FM / ................................................www.acument.com ..........................................................01925 811 243Avdel UK Ltd..........................................................................................................FM / ................................................www.acument.com ..........................................................01707 292 093Barton Cold-Form Ltd......................................................................................FM / ................................................www.coldform.it ................................................................01905 772 021Baylis Automotive (Smethwick) ................................................................FM / ................................................www.baylisautomotiveuk.co.uk ..................................0121 500 4200Bedford Steels ........................................................................................................FM / ................................................www.bedfordsteels.co.uk ..............................................01246 299 100Berck Ltd ..................................................................................................................FM / ................................................www.bercklimited.co.uk ................................................0121 553 2726Bharat Forge Ltd ..................................................................................................OM ................................................................................................................................................00 91 212 671 666Bharat Forge Scottish Stampings Ltd ....................................................FM / ................................................www.bharatforge.com ....................................................01292 267 971Bifrangi UK Ltd ....................................................................................................FM / ..................................................................................................................................................01522 585 800Bodycote Heat Treatments Ltd ..................................................................AM / ................................................www.bodycote.com..........................................................01625 505 300Brockhouse Group Ltd ....................................................................................FM / ................................................www.brockhouse.co.uk ..................................................0121 556 1241Calsonic Pressings Ltd ......................................................................................FM / ................................................www.calsonic.eu.com ......................................................0191 417 0084Caparo Atlas Fastenings Ltd ........................................................................FM / ................................................www.atlasfastenings.com ..............................................0121 224 2000Carlton Laser Services Ltd ............................................................................FM / ................................................www.carltonlaser.co.uk ..................................................0116 233 9990Carrington Wire Ltd ..........................................................................................AM / ................................................www.carringtonwire.com ..............................................01422 372 372Cerro EMS Ltd ......................................................................................................FM / ................................................www.cerro-ems.com ........................................................01922 476 641Chapmans Agricultural Ltd ..........................................................................FM / ................................................www.chapmans-uk.com ................................................0114 285 6000Chesterfield Special Cylinders Ltd ..........................................................FM / ................................................www.chesterfieldcylinders.com....................................0114 242 7500Chesterfield Special Steels..............................................................................AM / ................................................www.chesterfield-special-steels.co.uk........................01246 451 666China Forging Industry Association........................................................OM ..............................................................................................................................................00 86 10 6846 5045Cirteq Ltd ..................................................................................................................FM / ................................................www.cirteq.com ................................................................01535 633 333Clevedon Fasteners ............................................................................................FM / ................................................www.clevedon-fasteners.co.uk ....................................0121 378 0619Clyde Fasteners Ltd ............................................................................................FM / ................................................www.clydefasteners.com................................................01355 225 451Clydesdale Forge Company ..........................................................................FM / ................................................www.clydesdale-forge.co.uk ........................................01384 252 587Cooper & Turner Ltd ........................................................................................FM / ................................................www.cooperandturner.com ..........................................01142 560 057Cooper B-Line ........................................................................................................FM / ................................................www.cooperbline.co.uk ..................................................01278 783 371Cooper Crouse-Hinds (UK) Ltd ................................................................FM / ................................................www.enclosures-crouse-hinds.uk.com ......................01795 889 146Cooper Lighting and Safety ..........................................................................FM / ................................................www.cooperindustries.com ..........................................01302 321 541Corus Construction & Industrial ..............................................................AM / ................................................www.corusconstruction.com ........................................01724 404 040Corus Group ............................................................................................................AM / ................................................www.corusgroup.com ....................................................01709 371 234Covpress Holdings ..............................................................................................FM / ................................................www.covpress.com ..........................................................024 7669 1000CPM ..............................................................................................................................OM ..................................................................................................................................................00 49 2407 95940Cramlington Precision Forge Ltd ..............................................................FM / ................................................www.cpfl-tvs.com..............................................................01670 716 811DavyMarkham Ltd..............................................................................................AM / ................................................www.davymarkham.com................................................0114 291 4212DavyMarkham Ltd..............................................................................................AM / ................................................www.davymarkham.com................................................0114 291 4212Derek Johnson ......................................................................................................AM / ................................................www.kespar.co.uk ............................................................024 76411 208Deritend Induction Services ..........................................................................AM / ................................................www.deritend.co.uk ........................................................01922 621 664Dielife Limited ......................................................................................................AM / ................................................www.dielife.com................................................................01642 221 133Doncasters Blaenavon Ltd ............................................................................FM / ................................................www.doncasters.com ......................................................01495 790 345Doncasters Bramah ............................................................................................FM / ................................................www.doncasters.com ......................................................0114 251 2102Doncasters Precision Forgings Ltd ..........................................................FM / ................................................www.doncasters.com ......................................................0114 285 8100Dorken MKS-Systeme GmbH & Co KG..............................................AM / ................................................www.doerken.de ..............................................................0121 745 8959Dorken MKS-Systeme GmbH & Co KG..............................................AM / ................................................www.doerken.de ..............................................................01299 271 451Durham Duplex ....................................................................................................FM / ................................................www.durham-duplex.co.uk ..........................................0114 243 2313Eu-Matic Div. of Multimatic Ltd ..............................................................FM / ................................................www.multimatic.com ......................................................024 7667 3333Euromarch Ltd ......................................................................................................AM / ..................................................................................................................................................01452 525 259Evenwood Industries Ltd ................................................................................FM / ................................................www.evenwood.co.uk ....................................................01388 832 556Ewald Dorken AG ..............................................................................................OM ........................................................www.doerken.de..............................................................00 49 2330 630Fabreeka International Inc. ..........................................................................AM / ................................................www.fabreeka.com ..........................................................01274 531 333Falcon Foodservice Equipment ..................................................................FM / ................................................www.falconfoodservice.com ........................................01786 455 203Finkl UK ....................................................................................................................AM / ................................................www.finkl.com ..................................................................0121 544 4506Firth Rixson Forgings Ltd ..............................................................................FM / ................................................www.firthrixson.com........................................................0114 219 3740Firth Rixson Forgings Ltd ..............................................................................FM / ................................................www.firthrixson.com........................................................0114 219 3694Firth Rixson Ltd....................................................................................................FM / ................................................www.firthrixson.com........................................................0114 219 3000Floform Ltd ..............................................................................................................FM / ................................................www.floform.co.uk ..........................................................01938 551 712Footprint Tools Ltd ............................................................................................FM / ................................................www.footprint-tools.co.uk ............................................0114 232 7080Ford Component Manufacturing Ltd ....................................................FM / ................................................www.fordcomps.co.uk ....................................................0191 428 6600Forge Tech Services Ltd ..................................................................................AM / ................................................www.forgetechservices.com..........................................0161 339 1120Forging Industry Association ......................................................................OM ................................................................................................................................................00 1 216 781 6260Fowlers of Bristol (Engineers) Ltd ............................................................FM / ................................................www.fowlers-eng.com ....................................................0117 942 2563Frank Dudley Ltd ................................................................................................FM / ................................................www.frankdudley.com ....................................................0121 452 8500Fuchs Lubritech (UK) Ltd..............................................................................AM / ................................................www.kspaul.com ..............................................................020 8345 5566Futaba-Tenneco UK Ltd..................................................................................FM / ..................................................................................................................................................01282 433 171G W Waite Ltd ......................................................................................................FM / ................................................www.gwwaite.co.uk ........................................................01229 582 046Genex UK Ltd ........................................................................................................FM / ................................................www.genexuk.co.uk ........................................................01922 710 050George Dyke Ltd ..................................................................................................FM / ................................................www.george-dyke.co.uk ................................................01902 366 365Gesipa Blind Riveting Systems Ltd..........................................................FM / ................................................www.gesipa.com ..............................................................01535 212 200GKN Driveline Birmingham Ltd - Hamstead Plant ....................FM / ..................................................................................................................................................0121 377 7000Glen Dimplex Home Appliances................................................................FM / ................................................www.gdha.com..................................................................0870 444 9919Griff Chains Ltd....................................................................................................FM / ................................................www.griffchains.co.uk ....................................................01384 569 415Grorud Group Ltd ..............................................................................................FM / ................................................www.grorud.com ..............................................................01207 590 471
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a l p h a b e t i c a l l i s t i n g s
COMPANY TYPE WEB TEL
Grove Metal Sections Ltd................................................................................FM / ................................................www.grovems.com ..........................................................01902 601 697Guala Closures UK Ltd ..................................................................................FM / ................................................www.globalcap-group.co.uk ........................................0121 533 6288H V Wooding Ltd ................................................................................................FM / ................................................www.hvwooding.co.uk ..................................................01303 264 471Hadley Industries Plc ........................................................................................FM / ................................................www.hadleygroup.co.uk ................................................0121 555 1300Havelock Europa Plc ........................................................................................FM / ................................................www.havelockeuropa.com ............................................01383 823 636Heartlands Extrusion Forge Ltd ................................................................FM / ................................................www.hef.co.uk ..................................................................0121 359 6861Helipebs Ltd ............................................................................................................FM / ................................................www.helipebs.co.uk ........................................................01452 423 201Henkel Loctite Adhesives ................................................................................AM / ................................................www.henkel.com ..............................................................01629 824 171Henrob Ltd................................................................................................................FM / ................................................www.henrob.com..............................................................01244 837 220Henry Williams Ltd ............................................................................................FM / ................................................www.hwilliams.co.uk ......................................................01325 462 722HHT (Midlands) Ltd ..........................................................................................AM / ................................................www.hht.co.uk ..................................................................0121 526 4771Independent Forgings & Alloys Ltd ........................................................FM / ................................................www.forgedinsheffield.com ..........................................0114 234 3000Institute of Sheet Metal Engineering ......................................................AM / ................................................www.isme.org.uk ..............................................................01785 716 886Integriti ......................................................................................................................FM / ................................................www.integriti.co.uk ..........................................................0191 263 8686IRIS Business Solutions [Chorus] ............................................................AM / ................................................www.iris.co.uk ....................................................................01274 851 577Japan Forging Industry Association........................................................OM ................................................................................................................................................00 81 3 3241 7661Johnson Machine & Tool Co Ltd ..............................................................AM / ................................................www.johnson-group.co.uk ............................................0121 568 8013Kimber Drop Forgings Ltd ............................................................................FM / ..................................................................................................................................................01384 414 500Kiyokuni Europe Ltd ........................................................................................FM / ................................................www.kiyokuni.co.uk ........................................................01952 292 920Koyo Bearings (Europe) Ltd ........................................................................FM / ..................................................................................................................................................01226 733 200Krupp Camford Pressings Ltd ....................................................................FM / ..................................................................................................................................................01554 772 233KTS Wire Industries Ltd ................................................................................FM / ................................................www.ktswire.com..............................................................0113 253 2421Lasco UK Agent ....................................................................................................AM / ..................................................................................................................................................01902 672 491Lasco Umformtechnik GmbH......................................................................OM ........................................................www.lasco.com ............................................................00 49 9561 6420Laser Process Ltd..................................................................................................FM / ................................................www.laserprocess.co.uk..................................................01543 495 000Leonardt Ltd............................................................................................................FM / ................................................www.leonardt.com ..........................................................01746 861 203Linread Northbridge ..........................................................................................FM / ................................................www.mckechnieaerospace.com ..................................01527 525 719Lonestar PRD Group Ltd ..............................................................................FM / ................................................www.prdholdings.com ....................................................01902 636 246Metsec Plc..................................................................................................................FM / ................................................www.metsec.com..............................................................0121 601 6000Mettis Aerospace Ltd ........................................................................................FM / ................................................www.mettis-aerospace.com ..........................................01527 406 400Micas Simulations Ltd ......................................................................................AM / ................................................www.micassimulations.co.uk ........................................01299 822 522Midlands Occupational Health Service..................................................AM / ................................................www.mohs.co.uk ..............................................................0121 601 4041Miking Ltd ................................................................................................................FM / ..................................................................................................................................................0191 415 5919Mills Forgings Ltd................................................................................................FM / ................................................www.millsforgings.co.uk ................................................024 7622 4985Milton Keynes Pressings Ltd ........................................................................FM / ................................................www.mkp.co.uk ................................................................01908 271 940MSI-Forging Division ........................................................................................FM / ................................................www.msi-forge.com ........................................................01302 366 961Musashi Autoparts UK Ltd ..........................................................................FM / ................................................www.musashi.co.jp ..........................................................01443 866 140National Machinery UK Ltd ........................................................................AM / ................................................www.nationalmachinery.eu ..........................................0121 585 9846Newelco Division of Inductoheat Europe Ltd ..................................AM / ................................................www.newelco.co.uk ..........................................................01633 263021Northern Automotive Systems Ltd ..........................................................FM / ..................................................................................................................................................01873 832 263Oerlikon Balzers Coating Ltd ......................................................................AM / ................................................www.balzers.co.uk............................................................01908 377 277Oilgear Towler Ltd ..............................................................................................AM / ................................................www.oilgeartowler.co.uk................................................0113 394 7300Ovako Ltd..................................................................................................................AM / ................................................www.ovako.com................................................................0121 709 0110Padley & Venables Ltd ....................................................................................FM / ................................................www.padley-venables.com ............................................01246 299 100Pandrol UK Ltd ....................................................................................................FM / ................................................www.pandroluk.com........................................................01909 476 101Parker Hannifin Ltd ..........................................................................................FM / ..................................................................................................................................................0121 550 6397Pearson Panke Ltd ..............................................................................................AM / ................................................www.pearsonpanke.co.uk..............................................020 8959 3232Pearson Panke Ltd ..............................................................................................AM / ................................................www.pearsonpanke.co.uk..............................................020 8959 3232Pianoforte Supplies Ltd....................................................................................FM / ................................................www.psluk.co.uk ..............................................................01604 862 441Pietro Rimoldi & C SRL ................................................................................OM ............................................................................................................................................00 39 0 331 504 449Planit Software Ltd ............................................................................................AM / ................................................www.planit.com ................................................................01225 721 330Portola Packaging Ltd ......................................................................................FM / ................................................www.portola-europe.com ..............................................01302 552 400PRD Fasteners Ltd ..............................................................................................FM / ................................................www.prdfasteners.co.uk ................................................01902 639 160Premier Stampings Ltd ....................................................................................FM / ................................................www.premierstampings.co.uk ......................................01384 353 100Pressed Metal Products Ltd ..........................................................................FM / ................................................www.pressed-metal.com ................................................0121 555 6061Presspart Manufacturing Ltd ......................................................................FM / ................................................www.presspart.com..........................................................01254 584 126Presstrade GmbH ................................................................................................OM ........................................................www.presstrade.com........................................................01788 890 055Professional Polishing Services Ltd ..........................................................AM / ................................................www.professionalpolishing.co.uk................................0121 555 6569Rawlplug Ltd ..........................................................................................................FM / ................................................www.rawlplug.co.uk ........................................................0141 638 7961Rical Group..............................................................................................................FM / ................................................www.ricalltd.com ..............................................................01384 569 283Rical Group..............................................................................................................FM / ................................................www.ricalltd.com ..............................................................0121 555 4807Rittal-CSM Ltd ......................................................................................................FM / ................................................www.rittal-csm.co.uk ......................................................01752 207 600Rollins Bulldog Tools ........................................................................................FM / ................................................www.bulldogtools.co.uk ................................................01942 244 281Ross UK Ltd ............................................................................................................AM / ..................................................................................................................................................0121 559 4900Royal Bank of Scotland ..................................................................................AM / ................................................www.rbsif.co.uk ................................................................0121 262 7409RSM Industries Ltd ............................................................................................FM / ................................................www.rsmindustries.co.uk ..............................................024 7636 2082Schaeffler (UK) Ltd ............................................................................................FM / ................................................www.schaeffler.co.uk ......................................................01554 747 748SEMTA........................................................................................................................AM / ................................................www.semta.org.uk............................................................01923 238 441Sertec Ltd ..................................................................................................................FM / ................................................www.sertec.co.uk ..............................................................01675 463 361Shakespeare Forgings Ltd ..............................................................................FM / ..................................................................................................................................................01384 632 420Shakespeare Forgings Ltd ..............................................................................FM / ..................................................................................................................................................01384 632 420Smethwick Drop Forge Kidderminster..................................................FM / ..................................................................................................................................................01562 823 451Smith Bullough ......................................................................................................FM / ................................................www.smithbullough.com ..............................................01942 520 250SMS Meer GmbH ................................................................................................OM ........................................................www.sms-eumuco.de ....................................................00 49 214 7340SMS Mevac UK Ltd............................................................................................AM / ..................................................................................................................................................01606 551 421Solid Stampings Ltd ..........................................................................................FM / ................................................www.solidswivel.co.uk ....................................................01384 636 421Somers Forge Ltd ................................................................................................FM / ................................................www.somersforge.com ..................................................0121 585 5959South Wales Forgemasters ............................................................................FM / ................................................www.swforgemasters.co.uk ..........................................029 2081 0341Special Forged Products ..................................................................................FM / ................................................www.specialforgedproducts.com ................................0114 2560 914
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FM: Full member AM: Associate member OS: Overseas member / fasteners forging sheet metal
Spromak Ltd............................................................................................................FM / ................................................www.spromak.co.uk ........................................................0151 480 0592SPS Aerostructures Ltd ....................................................................................FM / ................................................www.spstech.com ............................................................0115 988 0185SPS International Ltd........................................................................................FM / ................................................www.spstech.com......................................................00 353 6171 6560SPS Technologies (T.J. Brooks Div.) ........................................................FM / ................................................www.spstech.com ............................................................0116 274 4980Stadco Castle Bromwich..................................................................................FM / ................................................www.stadco.co.uk ............................................................0121 382 3120Stadco Powys ..........................................................................................................FM / ................................................www.stadco.co.uk ............................................................01691 648 561Stadco Shrewsbury ..............................................................................................FM / ................................................www.stadco.co.uk ............................................................01743 462 227Steel Service Centre Ltd ..................................................................................FM / ................................................www.steelservicecentre.co.uk ......................................01889 270 241Stokes Forgings Dudley Ltd ..........................................................................FM / ..................................................................................................................................................01384 342 550Stokes Forgings Ltd ............................................................................................FM / ................................................www.stokesforgings.com ..............................................01922 704 800Strayfield Ltd ..........................................................................................................AM / ................................................www.strayfield.co.uk........................................................0870 428 1086Swann-Morton Ltd ..............................................................................................FM / ................................................www.swann-morton.com ..............................................0114 234 4231T W Stamping Ltd ..............................................................................................FM / ................................................www.twstamping.co.uk ..................................................0121 622 2600TEK Personnel Consultants..........................................................................AM / ................................................www.tekpersonnel.co.uk................................................0114 252 5730The Bifurcated & Tubular Rivet Company ........................................AM / ................................................www.bifandtub.co.uk ......................................................01296 314 300The Regent Engineering Co (Walsall) Ltd ..........................................FM / ................................................www.regenteng.com........................................................0121 526 6060Thornton Precision Components Ltd......................................................FM / ................................................www.tpcl.com ....................................................................0114 285 5881Thyssenkrupp Tallent Ltd ..............................................................................FM / ..................................................................................................................................................01325 313 232ThyssenKrupp Woodhead Ltd ....................................................................FM / ................................................www.thyssenkrupp.com..................................................01132 441 202Timet UK Ltd ........................................................................................................AM / ................................................www.timet.com..................................................................0121 356 1155Tinsley Bridge Ltd ..............................................................................................FM / ................................................www.tinsleybridge.co.uk ................................................0114 2211 111TKA Body Stampings Ltd..............................................................................FM / ..................................................................................................................................................01543 466 664TKA Bourn Plant ................................................................................................FM / ..................................................................................................................................................01954 213 200Towergate Risk Solutions................................................................................AM / ................................................www.towergate.co.uk ....................................................0116 240 5300TTI Group Ltd ......................................................................................................AM / ................................................www.ttigroup.co.uk..........................................................0121 327 2020Tucker Fasteners Ltd ........................................................................................FM / ................................................www.emhart.com..............................................................0121 356 4811Turton Springs Ltd ..............................................................................................FM / ................................................www.turtonsprings.com..................................................0114 270 1577UYS Ltd......................................................................................................................FM / ................................................www.uys.ltd.uk ..................................................................01865 334 860Vaughan Jones Socket Screws Ltd............................................................FM / ................................................www.vaughanjones.co.uk ..............................................01937 843 298Victoria Drop Forgings Co. Ltd..................................................................FM / ................................................www.victoriaforgings.co.uk ..........................................01902 605 141VTL Automotive Ltd ........................................................................................FM / ..................................................................................................................................................01422 882 561W & P Forgings ....................................................................................................FM / ................................................ www.wp-forging.co.uk..................................................01482 323 089W. H. Tildesley Ltd..............................................................................................FM / ................................................www.whtildesley.com ......................................................01902 366 440Walsall Pressings Co Ltd ................................................................................FM / ................................................www.walpres.co.uk ..........................................................01922 721 152Whiston Industries Ltd ....................................................................................AM / ................................................www.whistonindustries.com ........................................01384 560 606William King Ltd ................................................................................................FM / ..................................................................................................................................................0121 500 4121Wyman Gordon Lincoln Ltd ........................................................................FM / ................................................www.wyman-gordon.com ............................................01522 525 492Wyman Gordon Ltd ..........................................................................................FM / ................................................www.wyman-gordon.com ............................................01506 446 200X-met Fabrication & Finishing Ltd ........................................................FM / ..................................................................................................................................................01698 733 533Yorkshire Fittings Ltd ......................................................................................FM / ................................................www.yorkshirefittings.co.uk ..........................................0113 270 1104
COMPANY TYPE WEB TEL
Forging19th International
Forging
Conference
page 12
FastenersThe Titanic -
A riveting
storypage 11
EnergyPro Enviro
energy
challenge
page 6
Sheet MetalThe history
of
dry films
page 15
SteelThe outlook
for
stainless steel
page 21