Congratulations to Kenard Engineering for winning the Metal Working Production Best Subcontractor - Machining award. The judges gave their reasons for selecting Kenard as:

'Ticks all the right boxes - investment in advanced manufacturing, workflow management, input to design and development, lean principles, quality management - and marketing'

Kenard Engineering Company is a precision mechanical engineering company founded in 1964. Operating from two sites including a modern purpose built factory in Dartford and a facility in Tewkesbury. Kenard has 32 CNC machine tools between both sites, maximum turning capacity of 930mm diameter to a length of 3000mm, and both vertical and horizontal multi pallet machine centres with 800mm cube. The company manufactures one-off prototype  components through to medium batch (200 off) production requirements.

Kenard specialises in manufacturing precision components using modern manufacturing methods, using state of the art manufacturing equipment to offer engineering, manufacturing, sub and final assembly, electronic assembly, testing and sheet metal facilities. The main strengths of  the company reside in the flexibility provided by operating two manufacturing sites and the breadth of skills and knowledge held within the company.

The customer base generally promotes manufacture to order; however a number of supply agreements are now in place to facilitate a call off of components, reducing lead times and ensuring the customer has fixed pricing for an agreed period. Delivery performance is monitored on a customer by customer basis and overall performance is reviewed monthly by the management team.

A ‘Design for Manufacture’ facility is an integral part of the Kenard Engineering operation and works closely with the sales, production and quality functions to carry out detailed evaluations of their customers’ design department; individual design/manufacturing analysis of components and assemblies; manufacturing evaluation and process selection; material selection options; assessment of service condition and life expectancy requirements; surface finish requirements and options available; and special requirements (inspection/testing/packaging etc).

The company has a real time monitoring system directly linked to all the work centres; the data collected is reviewed at each stage of the manufacturing process. A comparison is made between Estimated/Planned/Actual process times; this in conjunction with effective supply chain management ensures the customer receives competitive and cost effective solutions. Machine tools are grouped together in relation to product size which reduces product movements and enhances smooth work flow. Each work centre has an electronic ‘work to list’ which automatically prioritises the next component on every work centre. Customer reporting is generally performed by project engineers using electronic data from the manufacturing system. However specific customers have access to the scheduling system which indicates via  a traffic light system if the product is on schedule.

Investment in the latest low or totally unmanned production capabilities is a priority and a the Tewkesbury facility, a line of five, four axis Mitsubishi MH 500 horizontal machining centres with 12,000rev/min spindles are installed as part of a 72 pallet flexible manufacturing system (FMS). The FMS is currently producing aluminium casings and steel valve blocks unmanned using full in-cycle probing and sister tool replenishment. The system, with its scheduling software, is set up to produce frequent or repeat batch orders as small as two or three parts against short delivery times. As a result, contracts are being won due to the high efficiency of the line and the ability of Kenard to respond quickly to short order demands.

The ongoing developments to extract energy from greener, naturally renewable sources has been accelerated due to the climate change challenge that the world faces. Energy from wind is one sector that has seen rapid growth, with Europe at the hub of this booming high-tech industry.  This growth can be seen from the first commercial wind farm in the UK, built in Cornwall in 1991 using 400 kW turbines, and today there are around 2000 onshore and offshore energy generating turbines operational in the UK. With the latest trials of large diameter turbines providing over 4 MW each. Within the nacelle of a wind turbine there are sets of bearings in the drive-train that allow the transfer of the rotation of the blades via a gearbox back to the generator. There is also a large bearing fitted at the base of each blade where it is attached to the hub. These allow the pitch of the blade to be trimmed according to wind conditions, to maximise energy extraction and stop any torque overload during high winds. Such has been the uptake in this renewable source of energy that globally there is a shortage of the large diameter special bearings required to construct these highly efficient power generating systems. As a supplier to the companies that manufacture these bearings, Sheffield-based Pen Cutting Tools is aware of this situation and is constantly under pressure to deliver.

Established in 1963, the company’s main core of customers reads like a who’s who of the industrial bearing sector, and wind turbines currently represent the majority of the challenges, and revenue. Managing director, John Shaw, explains: “Many of the bearing suppliers are investing heavily to support renewable energy projects, with wind and wave power generation being the most favourable at present. There is currently a world shortage of the large bearings typically used in wind turbine equipment. These bearings can go up to a staggering 4 m in diameter and there is currently a three-year wait for any large diameter bearings.”

Pen Cutting Tools has the capacity to produce tooling and driving units for the manufacture of bearing products up to 600 mm diameter, which would typically cover most of the bearings currently used on wind farms. The favoured design is twin spherical bearings, featuring two roller tracks designed for the relatively slow moving heavy loads.
To keep pace with demands Pen Cutting Tools has expanded its own production facilities building on from traditional milling, turning and grinding the company now has high-speed milling, 5-axis wire erosion and die sinking machines. All of these processes are used to finish parts from engineering plastics, tungsten carbide, diamond and hardened steel.
And, it’s not just the capital equipment that has seen investment to improve productivity. One of the company’s key purchases according to John Shaw has been its Enterprise Resource Planning (ERP) manufacturing software provided by Seiki Systems.

“The ERP system from Seiki Systems was purchased to replace an old manufacturing system, which we had run for around 15 years. We had a new IT hardware system installed with a networked server followed by the Seiki Systems software,” says John Shaw. In fact, Pen Cutting Tools was one of the first companies in the UK to install the ERP software and a full training package was provided to help the company get up to speed as quickly as possible. According to John Shaw the amount of time saved in the front office by the software is incredible. “From the data I input, the software automatically develops documentation in a logical way, from quotation to order right through to delivery note and invoice. It avoids the duplication that was taking place with our old system, keeping the whole process as streamlined as possible,” he states.

As the company runs mainly small batches, the quoting process can be a bottle-neck for the 25-strong company, with 22 of the staff working in production on the shopfloor. However, the search facility within the software allows similar jobs to be found and essential information, such as margins, hours booked and so on, viewed before any new quotes are provided. John Shaw adds: “Searching the many jobs that have been loaded on the system, within a couple of minutes I can get a good feel for the process time required for a job. Then I only need to update the material price. It requires far less running around to track down the information. The margin figure was set up for us by Seiki Systems. After we told them how we worked it out, they duplicated that in the system. It helps to highlight any jobs that were taken on at too low a price and allows you to quote more accurately the next time.”

Although accurately costing the wide variety of tooling required to produce tightly tolerance bearings is vital to the company’s profitability, a quick turnaround is also important. The lead time from design to production of a bearing use to take four to five months, the goal now is to do it in eight to 10 weeks, including prototyping and tooling for production. This is not easy when the material specified can have a three to five week lead time. To avoid any material-specific delays consignment stocks of wear parts and consumable tooling is held at the customer or by Pen Cutting Tools. This is charged when the stock is used and has helped the company win a number of contracts – running as a Kanban system for solid carbide shoes, hot forging tools and so on. A significant amount of raw materials is also held.

John Shaw say: “I’m aware that we don’t use every aspect of the ERP software but it’s very flexible and the elements we do use provide more than enough benefits. For example, I can now track our turnover as invoices are issued, on an hourly basis if I want, this is something we have never been able to do. Previously it would have been an end of week updated figure. The dynamic data allows us to alter what we are doing to stay on top of the business. It also keeps historical data so that we can track peaks and troughs to help us address issues that occur throughout the year.” The company will be looking at Seiki Systems scheduling system soon to help manage the machine loading on the shopfloor. And, if it is as flexible as the ERP software and able to fall in-line with how the company has to work with its customers it may well be the next investment Pen Cutting Tools makes.

John Shaw concludes: “From our point of view it has been an excellent investment, support has been first class. Seiki Systems makes sure we run smoothly and any issues we have with the system are address remotely, which saves time."

We will be previewing the latest version of the Seiki Networked Manufacturing System (NMS) software at MACH 2008. NMS V4.37 software, which has not yet been made available as a general release in the UK, has been enhanced to further assist manufacturers in their effort to become more ‘Lean’ by increasing production efficiency and by supporting continuous improvement strategies. In today’s business climate there has never been a more critical time to invest and secure manufacturing control and process advantage.

Seiki’s NMS system is modular and comprises of both manufacturing and business intelligence software which includes at the factory level, machine monitoring, job queue presentation, job recording, technical data distribution with DNC and probe data collection. The back office analytical suite offers machine status and alerts, machine performance analysis, job reporting and OEE, the key business tools that are necessary for effective work throughput management to achieve maximum utilisation of critical production resources. Seiki NMS is a powerful tool which provides live production management information and visibility to enable businesses to take a controlled as opposed to a reactive approach to the manufacturing process, both in the short term and sustainably into the future.

Many of the enhancements to NMS V4.37 have been made based on customer feedback to ensure that the solution satisfies the requirements of modern, forward-thinking manufacturing companies. The complete NMS terminal user interface and complimentary applications have been upgraded to give the product a modern fresh appearance. Additional features include barcode reader Code 39 compatibility for job logging and new capability to integrate with third party systems’ SFDC products. Many of the other enhancements included are not directly visible to the user but have resulted in overall speed and functionality improvements throughout the system, making the software extremely easy to implement and user friendly. These include a raft of overall speed improvements there is now a seamless, dynamic interface between the NMS terminal and the Seiki Scheduler.

Seiki Systems’ product range and solution offering is now wider than ever before and can support customer requirements from production planning, through to manufacturing execution and performance data capture with flexible and configurable functionality. This neat portfolio of products provides an immediate, visual and dynamic picture of the entire manufacturing process, and it is the modularity of the Seiki Systems’ solutions that produces the level of flexibility required by manufacturers to meet the ever changing demands of the industry and their customers. 

Benefits derived from the installation of Seiki Systems Networked Manufacturing System include:-

Seiki Systems will be exhibiting at MACH 2008, Stand 5151, Hall 5.

We are seeking a motivated and enthusiastic individual to be responsible for the implementation of our ERP and Scheduling solutions for our customers, ensuring a high degree of customer satisfaction in our products and services.

Production at hydraulic valve specialist Integrated Hydraulics is strictly ‘due-date’ led with output geared to meet order targets.  Before the installation of Seiki Systems’ iMES scheduling system, the process of  tracking down where a job was on the shopfloor used to take an average 30 minutes of precious management time followed by questions being asked to determine which operations had been completed and the estimated time for the batch to be finished.  Worse still, this often led to countless additional time spent debating the type of actions to be taken in order to respond to changing customer requirements. 

Outlined Tony Cave, senior production engineer:  “Following the installation in September 2006 of the Seiki Systems iMES scheduling system, which was fully integrated with our Sage Line 500 MRP system and the existing Seiki Systems Networked Manufacturing System (NMS), the internal phones have almost stopped ringing as people requiring production information now have live terminal access to the exact state of play.   Thanks to iMES, my team can now get on with their jobs,” he said.

Integrated Hydraulics is a £27 million business producing over 500 types of hydraulic manifold bodies for its range of screw-in cartridge valves and systems.  These are exported to 20 countries from the 28,000 ft2 Warwick factory to customers in the off-road, agriculture, earth moving, mining and construction sectors.  Most machining is carried out in-house on the three C Dugard-supplied Hyundai-Kia V50D vertical machining centres installed this year, Hitachi-Seiki horizontal machining centres and semi-automatic, special-purpose, six-spindle turret machines.

Most production schedules involve some 350 different jobs with around 22 new jobs loaded daily.  Each morning at 7 am the server for Seiki Systems iMES scans the MRP system for new orders and repeats its cycle 12 hours later in order to assemble the new business into a passive job queue. The Seiki Systems iMES then interfaces with the NMS software to update the job queue from activities and, behind the scenes, checks the activities carried out over the previous 12 hour period, then automatically re-plans the workload on the shopfloor. All new jobs are allocated according to production engineering layouts to individual machines based on delivery date and the iMES software checks for material, tooling and program availability and immediately flags an order requirement to the supervisor if details are missing or if there is a warning of a possible problem. Should the first choice machine be overloaded in terms of capacity, the system then informs supervision of viable options, depicts the second choice route and outlines its viability.  If program and tooling are available it will then import the relevant information.  Then, according to the scheduled start date to meet the delivery target, a list of tooling requirements is automatically transmitted to the tool stores ready for kit marshal and machine setting.

Through iMES, which has terminals in all key departments, and beside each machine tool, a colour coded screen planning board for each machine communicates current production information in a bar presentation format over the 24 production hours available each day, and creates the actual and future machine loading.  Holidays, planned maintenance and setting time are included and any changes that influence the flow of work, such as inspection stoppage or breakdown, are immediately identified to provide a warning and live update of any roll-on effect of the scheduled work in the form of delays.  Through a time view screen, decisions can be made from showing the roll-on effects of jobs being moved or batches split between machines in order to recover a situation with instant feedback on effects to existing works orders being processed.  The software uses a traffic light system to quickly identify the progress of each job: green depicts due day target OK, a light green warns that the job will be a close call with yellow used for ‘just in time’.  Once the screen changes to orange, delivery is one week behind and red shows some serious remedial action will be required to bring work back on track.

Back on the shopfloor operator co-operation is paramount to which Tony Cave adds:  “Everyone can see the benefit of iMES and the operator simply ticks the appropriate route card on the screen when the job is started, if there is a hitch or delay, or the run is completed.  Because tools, program and material are prepared prior to setting on the machine, waiting time is limited and through the iMES queuing system, it lets the operator know what is on the agenda and the urgency.” The previous planning board system was based on a single resource of CNC machines and could not track other processes such as deburring, washing etc to show a completed process log of the part.  As a result, there was limited information available once work was in progress.  And as Tony Cave describes, everyone used the telephone, or worse still, emails flew around the company requesting information. Data was input manually and any immediate problems were satisfied with the work being shuffled to try to meet targets.  However, this had little regard to longer term repercussions and resulted in the moving of problems further down the line. Today, anyone who needs to know can see, within one minute (the routine scanned update cycle from NMS to iMES) the exact state of production and even the sales team has the facility to check online to know exactly where any customer order fits into the ‘due-date’ schedule. In his production engineering role Tony Cave now has a fast track update, not only for program requirements and tooling problems but information on machine and process reliability.  And rather than rely on ‘gut feel’ that additional capacity or a replacement machine is required and the changes in work loading, he has factual information to initiate special attention, justify a purchase, or seek additional capacity through subcontract. Indeed, it was through iMES that the first Hyundai-Kia V50D was justified and once installed, such was its performance and high level of utilisation recorded by NMS, that two further machines were ordered from C Dugard.

On a weekly basis iMES sends an electronic delivery report to management giving an update of ‘due date’ situations and operations waiting to be completed. The weekly report is created to cover overall production and each machine showing production, alarms, maintenance, programming, waiting setting and housekeeping with at-a-glance pie chart breakdown. In addition, the full integration of NMS to iMES provides the vital link to traceability due to its factual reporting system.  Integrated Hydraulics knows the CNC program used on any job when it is returned from the machine via DNC where it is then compared to the original download to check any changes made.  The old program is then archived if approved by production engineering or an investigation carried out should there be a problem envisaged from any changes made on the shopfloor.  Tony Cave puts great store by the availability of the electronic diary that is a compendium of notes of operator actions, thoughts or comments and any problems or changes that are now archived with each job for reference on future batch runs. Also, records are made of production and quality data, original planned times and costs that are laid out against actual production achievement data.  Information is also recorded on machine history, materials and tooling to which Tony Cave adds:   “Used properly this is very important because no one will remember what happened even just a few days ago.”

Tony Cave’s development of the system is still progressing and here the modularity of iMES is able to support the growth and development of companies.  For Integrated Hydraulics the next stage is to build into the system subcontract operations to track, record and monitor the processes in the same way as internal production is recorded.   As a result, important information will be provided for management decisions either to put uneconomic tasks outside, or draw back in-house operations that need tighter control.

Read more about the Seiki Scheduler

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Our partners in the USA, JobPack Inc will be exhibiting at the South-TEC Show (IMTS) from 02 - 04 October 2007, followed by the Canadian Manufacturing Technology Show from the 15th-18th October.

South-TEC
The event promises to be the biggest yet featuring 90,000 square feet, 330 exhibits and a full technical conference. It will also feature Manufacturing for Performance exhibits geared towards motorsport manufacturers.

Exhibition details:-
Dates 02-04 October 2007
Venue Charlotte Convention Center, Charlotte, North Carolina, USA
For further details about the event, including pre registering, reasons to attend and a full list of exhibitors please visit the South-TEC website www.sme.org and follow the link from the Events and Expositions tab.

Canadian Manufacturing Technology Show
The Canadian Manufacturing Technology Show is the definitive exhibition of machine tools, automation technologies, production methods, management strategies and more. Places are limited so be sure to reserve your place early.

Exhibition details:-
Dates 15-18 October 2007
Venue Direct Energy Center, Toronto, Ontario
For further details about the event, including pre registering, reasons to attend and a full list of exhibitors please visit the CMTS website www.cmts.ca

Registration has now opened for MACH 2008. With floor space already sold out this promises to be one of the biggest and best MACH shows so far. Make sure to plan your visit early and register now via their website www.mach2008.com

Seiki Systems will be exhibiting in Hall 5, Stand 5151.

Our German partners Fauser-AG will be exhibiting at EMO Hannover and Seiki Systems will be joining them on the stand to demonstrate our shopfloor systems.

Make sure you visit us on stand F18 in Hall 6

Don't forget to add these dates to your diary!

As part of our drive to improve our overall business Seiki Systems are delighted to advise that we have appointed JCNC Ltd as our exclusive distributor for Ireland.

JCNC Ltd  is a new company set up by James Fletchmore who has extensive experience of Machine Tool sales, applications and support together with comprehensive knowledge of the Irish manufacturing industry. James will be offering the complete range of products offered by Seiki Systems and we look forward to his future success in Ireland.

If you are based in Ireland and would like to discuss any of Seiki Systems products then please contact James directly on: Tel: +353 (0)45 438272   Fax: +353 (0)45 438272

Due to the strong interest in our upcoming Performance Workshop the morning session is now full and only a handful of spaces remain for the afternoon session. Please contact Jamie (tel: 01273 680411) now to secure your place at the free workshop on the 12th July. As an additional benefit we have now also included an optional tour of the Renishaw Stonehouse facility for all those registered to attend the afternoon session.

For more in formation and an agenda visit www.seikisystems.co.uk/performance. If you are unable to attend on the day but would like information pack please email marketing@seikisystems.co.uk, please also indicate if you would like to be notified as soon as the date for the next workshop is confirmed.

Delivery
Quality
Profitability

Control production to meet delivery dates
Control the process to prove quality standards
Control costs to enhance profitability

To survive in the competitive environment of modern manufacturing it is essential to have integrated solutions that can enable you to manage your production simply and with confidence. Just as important is implementing tools and systems that will enhance your business; supporting the way that you work and allowing you to benefit from productivity improvements. Together we aim to help you to identify ways in which you can take control.

This will be a joint presentation by Seiki Systems, GS Productivity Solutions and Renishaw. There will be two sessions on the day:

Morning session 9.30 to 12.15
Afternoon session 13.00 to 15.30
(please indicate which session you will be attending when you register)

An optional visit to the Renishaw Stonehouse facility will take place in the afternoon for all those registered to attend the morning session. Again you will be asked to register your intention to take part in this visit on the registration form. Lunch will be provided between 12.15 and 13.00 for both morning and afternoon attendees.

Agenda for each session

Introduction
Production management and process control
Practical demonstrations & refreshments
Probing on a machine tool - Get it right!
Manufacturing intelligence and performance measurement

This is a great opportunity to discuss with our specialists ways in which your company can take control of the key issues of meeting delivery requirements, quality performance and enhancing profitability.

Venue:            Renishaw plc
                        New Mills
                        Wotton-Under-Edge
                        Gloucestershire
                        GL21 8JR

Date:               12 July 2007

Time:               9.30 – 12.15 or 13.00 to 15.30

If you would like to attend please click here to register. Alternatively telephone 01273 602564 or email to: jamiew@seikisystems.co.uk. There are a limited number of spaces available so be sure to book early.

Contacts

Seiki Systems Ltd
Tel: 01273 680411
Email: sales@seikisystems.co.uk
Web: www.seikisystems.co.uk

GS Productivity Solutions
Tel: 01454 261500
Email: info@gspsltd.co.uk
Web: www.gspsltd.co.uk

Renishaw plc
Tel: 01453 524524
Email: uk@renishaw.com
Web: www.renishaw.com

Seiki Systems NC Program Manager is an entry level system, comprising of a powerful text editor for creation and editing of NC programs, together with configurable communications to enable DNC transfer between the CNC machine and a desktop or laptop PC.

It has been specifically developed to meet the needs for creation, management, editing and transfer of NC part programs, all in a Windows® environment. The software uses the standard Microsoft Windows Explorer® for management and file selection which has the additional benefit of eliminating the need to continuously type the required field names. NC Program Manager is ideal for small machine shops or for use as a back-up system. Visit our NC Program Manager page for more information and instructions for downloading the software.

Congratulations to Kenard Engineering who came highly commended in the Best ROI measures and benefits from IT in Plant and Factory Improvement category in the Manufacturing Computer Solutions Best of British Manufacturing Awards 2007. It has been the installation of the totally integrated manufacturing system iMES from Seiki Systems that has enabled the company to control work flow and respond to customers, reduce work in progress and make the best use of the production resource of 15 CNC machines.

The awards are designed to recognise efforts for manufacturing and engineering business excellence through the use of good IT intelligently implemented and for achievements in terms of hard, measurable ROI and business benefits.

www.bestofbritishmfg.co.uk

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Within eight months of integrating Seiki Systems’ Network Manufacturing System (NMS) with its Graphical Real Time Scheduler to provide automatic machine monitoring and works order control, Rayburn Plastics has made massive improvements to business efficiency.  As an example, inventory has been reduced by £50,000, daily throughput has risen by 25 per cent to almost £16,000 per day, machine utilisation has improved by 10 per cent, order backlog has been reduced from around £350,000 to £80,000, and on-time delivery improved.  Indeed, the company has now achieved its 2-3 per cent month-on-month improvement target over the last six consecutive months.

When managing director David Andrews took over at Rayburn Plastics two years ago business projections were looking bleak.  “We had to achieve profitability, reduce lead time and improve delivery performance – otherwise our two main customers (suppliers to power generation and aircraft interiors) that represented 65 per cent of our order book, plus a further 50 customers in other market areas, may have slipped away.”

The company, he says, had stagnated:  “It had progressively fallen behind on deliveries and had become a reactionary society with virtually no control or planning when new orders came in.”  With a business focused on firefighting and forever trying to put things right, the company did not have the resource to start planning ahead and it did not have the time to build up proper records: historical information was held in everyone’s heads.    “The business was almost working blind.” he said.

Appointed managing director in November 2004, Mr Andrews’ who has extensive automotive management expertise was charged to transform the business to achieve profitability and growth using automotive standards of performance. Having previously worked at the Walsall-based company - he left in 1980 to further his career - his immediate action as managing director was to try to understand why day-to-day problems dominated activities.  His vision for the company was to adopt well-proven automotive industry techniques and adapt them to create an operational strategy that would introduce a new culture to the business.

Mr Andrews wanted a plan that involved shared information, a discipline of working to set procedures and the involvement of all the people employed in the success of the operation.  This, he felt, was the only way to progressively turn the ailing company around.

Twelve months down the line and the culture change was beginning to be implemented, including £100,000 investment in a new Sage 500 system that included MRP. But, he says, there were still ‘holes’ in the control of production, so Terry Franks was appointed production manager charged to integrate the manufacturing operation into the overall business control system. 

From his previous company Mr Franks had seen how Seiki Systems’ NMS had become a powerful tool in providing live production management information.  He recommended that not only would the hole in the ‘overall control’ be bridged, but that NMS would also provide the very tool the company needed to stem its reactionary attitude to orders and progressively move to one that would allow the selling of spare capacity and decline orders for which there was not sufficient capacity.

Seiki Systems’ NMS and scheduler was installed in April 2006 and was integrated by the Brighton-based manufacturing systems supplier to the Sage 500 MRP to enable overnight data interchange between the systems.  As Mr Andrews explains: “The Seiki software gave us the tools to dig ourselves out of the mire.  With Seiki Systems help we were able to control the whole manufacturing operation, involving 48 individual work centres, to handle the 1,600 live parts on file incorporating around 14,000 separate operations.  Only a few orders are repeat or contain ‘similar to’ parts – and for power generation customers, we rarely produce the same part twice.” 

Rayburn Plastics, which employs 58 people and sales of £3.6 million, is owned by Alan Griffiths having been set up by his father more than 40 years ago as a plastics machining company.  It evolved into CNC machining of plastics and composites and in response to market changes expanded into machining aluminium and copper components for the aircraft and power generation sector.  As the business has progressed, 90 per cent of activity  is now dedicated to CNC machining, with some fabrication and assembly of the plastics parts produced for markets that include aircraft interiors.

Amongst the company’s other claims to fame are the production of coin tubes for slot machines and a contract with British Waterways using recycled nylon to produce the parts and finish assemble lock gates for the UK canal system.

For years the company had never documented operating procedures, production routes or setting information and it is here that one of the immediate benefits of the Seiki Systems’ installation was highlighted: all relevant job information could be easily pulled into product files linked to CNC program control relevant to latest drawing issue.  The DNC control of programs alone has already reduced set up time by 10 per cent. 

Tool control and readily available setting and tool kitting, as well as process details including video recordings of certain procedures along with digital photographs and illustrations of set-ups are now captured on file, in addition to process information, speeds, feeds and cycle times.  As a result, says Mr Andrews: “We now have vital information to start to implement lean manufacturing techniques.”
Already Rayburn Plastics has increased efficiency by 20 per cent because its people know what to do, how and when to do it.  “This has made a massive improvement to our organisation and will continue to have an influence on the business as more jobs are brought into the system.  We can also move people between jobs because the relevant information is readily available, giving us tremendous flexibility and operators that are more interested in their tasks.  As a result, the whole workforce has bought into the scheme,” he says.

The Seiki Systems’ terminals are strategically located in the heavy machining, light machining, fabrication and assembly areas to provide setting information and job scheduling so everyone has access and can prepare and tool kit the next job while an operation is being run.

Meanwhile, in the operational planning office, the Seiki Systems’ technology enables work to be planned.  Once material, tooling and CNC program data is available, the system takes the delivery date from the MRP system and tracks forward to start date according to machine loading.  Once agreed, it will only allow material issue to the shopfloor on the start date.  “This has meant a massive reduction in material inventory with £50,000 saved in just six months,” says Mr Franks, “and this alone has more than funded the investment in the Seiki Systems installation.”

As jobs progress, operators log on and off giving production control immediate, and therefore, ‘live’ information enabling ‘real time’ throughput to be monitored and controlled.  “We are managing our workflow, we know precise delivery dates and can plan new jobs effectively as we progressively decrease our order backlog.  In just six months, throughput has increased from £13,000 per day to £15,900 with rarely an end of month rush to boost invoicing,” says Mr Andrews.  “And,” he says, “we know exactly where our machines are overloaded or under-utilised, which has resulted in very useful information for our sales team to sell spare capacity.  That is a real bonus, a contributor to profitability and an effective boost to machine utilisation.” Reflecting on the installation, Mr Andrews says he can now understand why Mr Franks was so enthusiastic to introduce the Seiki Systems’ technology.  “It was exactly the right product at the right time. The support was excellent – we needed a lot of help and only had a short time to implement our plans.”

www.rayburn.co.uk

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Congratulations to Brian Trill who made it back safely from his trip to Peru.

Brian, our technical support engineer who is a keen cyclist, took on the Macmillan Peru Cycling Challenge. As many people will already know Brian was unable to take part in the 7 day trek last October as he sustained a broken leg just a week before he was due to fly out to Peru.
Now completely healed and back on his bike Brian flew out to take part in the challenge that starts at Lake Titicaca (the highest lake in the world) across remote altiplano and past snow capped mountains before finishing at Macchu Picchu—the famous ‘Lost City of the Incas’. This cycling challenge is to help ensure that Macmillan are able to continue to support cancer patients and their families.

If you would like to know more about the Macmillan cycling challenge and how you can support the cause visit their website: www.macmillan.org.uk

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Our partners in the USA, JobPack Inc will be demonstrating at the EASTEC Show (IMTS) from 22 - 24 May 2007. For 28 years EASTEC has been the premier manufacturing event in the Northeast of America.

Exhibition details:-
Dates 22 - 24 May 2007
Venue W Springfield, MA USA

For further details about the event, including pre registering, reasons to attend and a full list of exhibitors please visit the EASTEC website www.sme.org/eastec There is a section dedicated to International visitors with useful contact numbers and advice on where to stay in the area.

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Using a combination of the latest Internet technology and telephone conferencing, Seiki Systems is now able to carry out live demonstrations and presentations of its manufacturing software solutions direct from its Brighton headquarters.   By using remote links and two-way discussions, the requirements and working practices of the customer can be immediately incorporated into the Seiki Systems demonstration of the features available in its software for evaluation. 

Seiki Systems is a registered user of GoToMeetingTM that enables live demonstrations and presentations to be conducted or support provided to customers over a secure Internet connection.  This easy to use online meeting and support facility provides a greater degree of flexibility and convenience.

As general manager David Trowell describes: “With the special website access and discussions using conference calling we can talk to almost any country in the world, involve people in other customer departments or sites as well as calling upon our specialists to contribute whenever required.  This has already proven very beneficial in two recent projects in Canada and Jordan saving the costs and distractions of long distance travel to make presentations and adjustments to our proposals right up to the point of offers being accepted in principle.”

Seiki Systems developed the presentation technique with its partner in America where it is often inconvenient and impractical to gather all the participants in a single meeting.  In particular, Internet conferencing is proving very successful in effectively demonstrating its Networked Manufacturing and iMES scheduling software packages because it enables a customised presentation to be shown with graphical simulation of the customers’ workload for the machine tools that are available.  In addition, pertinent factors can be added to show the effectiveness of the software to handle any consequences of deliberate or unforeseen changes.

Says David Trowell: “This capability now also enables us to provide a major benefit to our customers by providing technical assistance almost immediately as our support engineers are able to remotely log onto a customer’s PC and provide advice, diagnose problems or help with changes.   Customers have responded by saying they appreciate this level of interactivity, while each party has the convenience of familiar working territory.  In particular, this is seen as an important benefit when dealing with complex technical issues that would be difficult to diagnose and resolve over the telephone,” he maintains.

Visit our support homepage

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Exo-View is a specialised software package developed specifically to enable component suppliers to integrate with Exostar, the system used by aerospace and aero-engine manufacturers to inform their subcontract suppliers of delivery requirements.

Exostar is an ideal solution to enable suppliers to forward plan but due to the large quantity of information and with no method of highlighting any changes simply and quickly, maintaining the system can be problematical.

Managing Exostar schedules normally requires a dedicated member of staff, usually a senior manager, to spend many hours each week to manually run through multiple spreadsheet pages, often containing hundreds of lines, to check for any changes from previous issues. The implications of error can be serious as they can cause production and delivery problems not only on site but also for the end user.

As the principal requests that the supplier confirm that they can comply to these changes or notify of any problems with quantities, prices or delivery dates by the end of the week it is essential that the information you have is up-to-date. This means co-ordinating the latest Exostar release with your production schedules, which when done on multiple spreadsheets and using paper based methods can be time consuming and often inaccurate.

Exo-View, the latest product release from Seiki Systems can automatically analyse the customer's requirements quickly and highlight any changes, a task that normally takes days when done manually. A traffic light system also alerts to any items needing immediate attention. Further to this the system is integrated to the Real Time Scheduler allowing you to view the exact position and status of W.I.P, obtain an immediate forecast of any possible late deliveries and longer term effects on production.

An article featuring Exo-View ran in the latest edition of Aerospace Manufacturing. To read this article you can either download the pdf here or visit their website www.aero-mag.com.

Visit our Exo-View homepage

If you are interested in learning more about this product contact us now to speak to your area manager. Email sales@seikisystems.co.uk

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To view the topics that were due to be discussed at the workshop please visit the SMART Production homepage www.seikisystems.co.uk/products/smartproduction.htm

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Seiki Systems manufacturing system now provides additional benefits for CNC machines equipped with Renishaw probes. By forming a partnership with GS Productivity Solutions we are now able to offer a number of new plug-in and compatible modules enabling you to maximise the benefits of CNC probing.

Just some of the benefits you can expect include:-

• Replace manual based data collection
• Improve overall quality and process confidence
• Reduce set-up times (90% reductions recorded)
• Reduce down-time due to "awaiting inspection"
• Reduce scrap cost and rework time
• Reduce Overall Inspection Overhead
• Auditable and traceable records
• Key enabler for Lights Out manufacture

Seiki Systems real-time probe data collection software automatically collects probing results from CNC machines equipped with Renishaw probes and a suitable data output facility. The collected data can be used to create text records or feed SPC systems using a unique configuration facility - Seiki Batch Script (SBS). This feature is now available as an option within the Seiki Networked Manufacturing (NMS) System*

GS Productivity Solutions CNC Reporter software is a user configurable Excel based sheet that generates real-time CMM style inspection reports. Individualised report templates that enable the creation of automatic control charts across critical features are easily generated within the macro based spreadsheet. The charts can contain customizable control limits, highlight out of tolerance features and monitor process variation to predict errors before they occur. The templates can provide sequential reporting across all components and provide a total traceable production history. This product is available as a "plug in" to Seiki NMS System*

*NB for automatic output the CNC must be fitted with an RS232 port and DPRNT or similar functionality

Download information sheet

Seiki Systems Networked Manufacturing System (NMS)
www.gspsltd.co.uk

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The first in a series of our SMART Production Workshops, designed to show benefits of integrated manufacturing software solutions, took place on the 16th November at the Trident Technology Centre in Warwickshire.

The workshop consisted of two presentations; Seiki Systems' speaker Neil Saunders identified ways in which you can manager the critical link between production efficiency and profitability and Guy Brown from GS Productivity Solutions demonstrated how to maximise the benefits of in process CNC probing. The presentations were followed by a buffet style lunch and time for one-on-one discussions with a member of our team. As well as providing an opportunity to see a demonstration of our full product range, the workshop also enabled some of our existing customers to meet and discuss their experiences.

SMART Production highlights the importance of managing business intelligence (BI) and manufacturing intelligence (MI) and how consolidating these two key areas can enhance the efficiency and productivity of a company. Seiki Systems and GS Productivity Solutions provide the tools to gather all the knowledge needed, based on real-time data, that will enable companies to make critical decisions based on facts. For example on the shopfloor this means that all essential, up-to-date information is made available at point of use and at management level automatically generated statistical analysis will highlight reasons for lost productivity and opportunities for improvement.

For details of SMART Production Workshops being held in your area please keep checking the website.

Westwind Air Bearings’ manufacturing plant in China has adopted Seiki Systems’ Enterprise Resource Planning (ERP) software as part of its Integrated Manufacturing Execution System (iMES) in order to maintain and manage high levels of production and to control and integrate production requirements with the Poole headquarters in the UK.

What makes the system so important is that it provides the solution to control over 50 different work centres and cells now operating at the plant in China.  This also includes material supply from the UK for critical components for example: bearings, thrust plates and bought-out items such as jets, bushes and screws, as well as the added complication of China sourced and machined components and spare parts.  In addition, control is also maintained over certain items machined in China for shipment back to UK where they are assembled, and for parts or assemblies for use in the Asian market.

Controlling production was a big issue when setting up the facility and while Westwind Air Bearings utilises an existing MRP system to plan overall production in both the UK and China, the Chinese initially made use of Excel spreadsheets for the very small quantities of initial components involved there.  But production is now more demanding with over 1,000 stock items, 100 individual orders a week and regular small batch machining involving between 12 and 50 parts. As Paul Berrett manufacturing systems engineer explains: “It would be totally uncontrollable with spreadsheets.”

This is no longer a problem however, as with the iMES production control software installed they are able to take complete control.  The software provides live information in a simple to follow graphical representation enabling ‘real time’ decision making.  Key to the system integration and operation is the Brighton software specialist’s Network Manufacturing System (NMS) that is also utilised via the easy to configure Seiki Systems Enterprise Application Interface Module (EAI) that enables dialogue with the Westwind MRP system in Poole.  Says Paul Berrett:  “We now have a single master for control – no out of date paperwork floating around and any manufacturing change is instant with immediate transfer.  This keeps everyone informed.”

The system went live in December 2005 with Paul Berrett as the liaison engineer  between the Chinese and two resident Westwind engineers that control, help train and provide the very strict quality control procedures Westwind has laid down. 

Established for some 40 years, Westwind Air Bearings of Poole has created an international leading operation producing air bearing systems largely for the PCB drilling and routing business.  Its high speed spindle design is an acclaimed world-leader in the technology able to run at up to 300,000 revs/min and can, according to the application, be powered by motors up to 20 kW.   A special range of Westwind spindles, with very low dynamic runout, are able to produce holes as fine as 0.050 mm diameter. 

The company’s spindles are also involved in semiconductor processing equipment used for wafer dicing, back grinding and notching as well as ion implantation and disk verification.  And, high speed spindles are also widely used for pre-press image setting processes such as scanning, image setting, divert imaging and internal drum rotary scanning, as well as completely divorced-applications such as for coating application, robotic and rotary spraying.  Such is the success of the company that it has won a Queen’s Award for Export and Technology Achievement on several occasions. 

In the UK, Westwind made good use of its existing MRP system installed in 2000 to plan production in China as well as at Poole.  All core planning for the site in China is still carried out in the UK with the Seiki Systems iMES production control/scheduling software installed in China having direct dial connections into the system from Poole. 

With the Seiki Systems’ solution, all UK order numbers (item checking number and bill of materials) are transferred through the EAI module into the iMES scheduler in a passive state with numbers required and due date depicted through an active disposition module.

This shows very simply in graphical display minimum stock levels. While green is satisfactory, any deviation stands out immediately as it is coloured coded red.  All production for GSI laser and encoder production is also scheduled through the Seiki Systems software.

In the work queue, once a module becomes active it changes colour to yellow to signify it is now work in progress and is then monitored by the iMES schedule against work centre and queue listing showing supply and demand balances as well as the situation with purchase parts. Running across the top of the screen is a graphical trace that also portrays the process path of any order number against time scales.

Data is transferred daily and is immediately updated. Says Paul Berrett: “Although the system is in English, the beauty is that it is so visual for the Chinese they can obtain an immediate status report just by glancing at the screen.“

The Seiki Systems NMS carries the job list then enables the operators in China to select the next job and pick the appropriate folder.  This contains all program data, a process sheet and stage drawing, a procedure document and even movie clips of certain areas of the process for added information.  Here Paul Berrett describes this feature as being highly beneficial when they were training the Chinese.

Indeed, training was important and here close liaison between Seiki Systems and Westwind proved its worth.  Training started in July 2005 at Poole involving key people which included the two Westwind engineers now resident in China.  They were given a temporary licence to trial the system and the server in China was configured in Poole with the Seiki Systems iMES, EAI and NMS software to enable initial data entries and communication to be performed. 

Within two weeks during September, the system was installed and nine shopfloor PC terminals set up for NMS, while training of the Chinese working with interpreters was completed.  Adds Paul Berrett:  “They were very quick to learn and quickly understood the concept, which is a further tribute to the system and the way we could work with it.”

Initially, dual systems involving Excel spreadsheets were run and by December, the system was live ready to start works order, purchase and sales operations.  In order to maintain control and to ensure everything is proven, any upgrades to the software are performed at Poole, tested, then rolled out to China.  The same regime is maintained for all bills of material, enabling control to be maintained in one place and all changes exported to China. 

The Seiki Systems ERP software is designed to keep the order management process as simple as possible and at each step enables users to view current order status based on live information.  This, at a stroke, allows critical decisions to be made based on immediate factual situations.

View iMES product page
View ERP product page
View Scheduler product page

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As manufacturing becomes increasingly competitive the pressure to keep costs low while maintaining the high standards demanded by industry and customers is growing. Seiki Systems and GS Productivity Solutions are inviting you to attend a free workshop that will guide you through our integrated manufacturing software solutions.

We guarantee that you will learn how your productivity can be improved!

The workshop will highlight:

The benefits of a real time work planning
Why measuring both performance and process is as critical as measuring parts
Accessing essential information to help reduce waste and improve lead times
How the use of these tools has shown a productivity improvement
of 5-10% in the average workshop

This is a unique opportunity to discuss with software specialist how our systems can be used to manage the constantly changing demands of day-to-day manufacturing, no matter how large or small your organisation.

• Reduce W.I.P and inventory
• Control work flow
• Increase throughput
• Reduce lead times
• Increase machine efficiency
• Fully informed and satisfied customers

 

Seiki Systems will identify ways in which you can manage the critical link between production efficiency and profitability by focusing on:-

• The advantages of real time graphical work planning
  > Manage the work load, set achievable dates and identify spare capacity
• The importance of an easy to use Shop Floor Interface
  > Display all manufacturing data and electronically collect performance data
• The benefits of management reports
  > Recognise trend, identify reasons for lost productivity and measure by OEE

GS Productivity Solutions will demonstrate how to maximise the benefits of in process CNC probing:-

• Reduce overall inspection factory wide
  > Start to measure the capability of your machining processes as well as your parts.
• Measuring the process
  > Understand how to utilise your existing on machine probing systems and how process
  control can be adopted by everyone
• Engineering Control
  > This is not a 6 sigma or SPC workshop - this is how machinists and engineers can
  take control of their processes in simple step

Venue:            Warwickshire College
                        Trident Technology and Business Centre
                        Trident Park
                        Poseidon Way
                        Warwick
                        CV34 6SW (map)

Date:               16 November 2006

Time:               9.30 – 13.30 (refreshments provided)

If you would like to attend please download the registration form and either fax back to 01273 602564 or email to: jamiew@seikisystems.co.uk. There are a limited number of spaces available so be sure to book early.

Warwickshire College: Trident Technology and Business Centre - visit their website
Seiki Systems Integrated Manufacturing System
For more information about GSPS Ltd visit their website

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JobPack Inc, our Partners in the USA, have just returned from an extremely successful IMTS 2006. The 8 day event in Chicago achieved its highest attendance for 6 years of 91,000 plus visitors, from over 40 countries; a six per cent increase in registered visitors from 2004. Over 4,000 of these visited the systems pavilion and this year JobPack too