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To be truly responsive, a sub contract facility needs to have a high level of autonomy; if we were dependent on a third party to supply essential materials or tooling then our ability to respond quickly to an urgent requirement could be significantly compromised. To provide a higher level of independence and thus a greater ability to react quickly Monolution have initiated an extended Material stocking policy and an automated tool management system.  Now holding extensive stocks of cast 5083, 2014 & 7075 aluminium, TB 650 tooling block & Epoxy EP 678, most of the urgent orders received can be serviced from our own in house resources, reducing or eliminating the normal lead time for these common materials.

Rationalisation and pro-active tool management ensures that we seldom need additional tool holders or inserts and our creative work holding techniques avoid the need for special fixtures or complex set-ups.

Without complete & comprehensive documentation even these measures will not allow a timely delivery.  Our dynamic real time  Progress Plus production management system, which is fully integrated with both the commercial and Quality systems, ensures it all comes together and avoids those commonly cited “administrative” delays.

With the inexorable shift to digital data and electronic communication the whole process of enquiry, quotation, order placement & fulfilment has been significantly foreshortened. CAD Data models are now the common currency of manufacturing and the ability to accept component dimensional & geometrical  information in the more  common  digital  formats, e.g. DXF, IGES, STEP, Parasolids,  Solidworks or  CATIA,  is an essential part of both the tendering and production process.

Efficiently translating  complex form and precise size to an optimised  cutting path during manufacture is the  primary  function of a good  CAM system. However, as it can also determine the time & resource requirements it is now often introduced at the quotation stage to effect accurate pricing and, in conjunction with the MRP system a realisable delivery.

A good system must  ensure  that close geometric tolerances can be  readily attained and that the required surface finishes are achieved. Moreover, being able  to  utilise  the PMI embedded within the CAD data Model to generate the most efficient  CNC programmes is a definite benefit to both us and our customers.  Outputting reliable NC code which requires little or no optimisation, especially for 5 axis programmes, is a demanding task and is why we use the Lemoine-RTM software to meet our challenging CAM  requirements. We now have five stations in operation, having added another  seat this year so that we can adequately support  the increased machining capacity .

Now just three years on, 70% of all orders passing through the shop demand or benefit from the application of true 5 axis  technology.  In response to this welcome development, Monolution  increased capacity to keep up with demand, purchasing a second machine in 2010 and are now about to take delivery of another two high specification VMC’s which will give them a total of four, full 5 axis, simultaneous machines.  These  latest additions come in the form of two, Deckel Maho DMU 50′s which will compliment and augment the  DMU 100 & DMU 60 already fully utilised on advanced  3D machining. The DMU 50 offers travels of X500, Y450 & Z400  with a 630 mm rotary table that can tilt through  115 degrees. Rapid traverse rates of 24M/min combine with a 10,000 rpm spindle and a 16 station tool carousel to provide a highly productive and  versatile tool. In common with the other installed machines this latest pair are both equipped with the excellent Heidenhain iTNC530  control.

In addition to increasing overall capacity the rotating /tilting table design of the DMU 50 enhances the rigidity and accuracy , especially beneficial when machining some of the more exotic materials, or where more demanding tolerances are stipulated. To maximise throughput it is essential to avoid scheduling conflicts and overloading the 5 axis resources, but  as roughing out  and tooling operations are usually done on the 3 axis machines it is equally important to have adequate provision for this as well. Maintaining the correct balance between critical 5 axis and 3 axis CNC capacity will now be the  key to our future investment plans.

We were fortunate to start the year with a very full order book which only got bigger during the first quarter. We had then expected thing s to quiet down a little,  slackening   towards the end of the second quarter, as in previous years . We could not have been more wrong; demand  actually grew  during this period as a number of new customers, discovering  our outstanding  level of expertise and service on initial projects, upped their subsequent order levels in response.

This has prompted us to bring forward  our planned  capital  investment  programme to providing additional capacity in the  third quarter  so we  can maintain our enviable reputation for prompt and accurate delivery times.

This decision was made easier as we have now fully implemented  our Progress Plus system giving  us a  highly accurate  view of  work in progress, the status of  outstanding  orders  and enabling  us to use truly optimised  capacity planning.  Performance data and trend analysis generated by the system helped identify the correct  type and timing for this investment.

But It’s not only investment in new machines that we identified, we also recognised the need to cultivate a skilled and adaptive workforce. We therefore took on an additional apprentice, we now have three at various stages of their training, in addition to attracting  more experienced CNC machinist to strengthen our establish team.

We are convinced that taking these important steps now  is in both our own best interest and those of our customers. We  hope it is seen as a measure of our commitment to maintaining our position as the Sub contract Machining specialist of choice for a growing number of you.

Were here to help and were definitely here to stay!

Taking out appropriate insurance is part of our normal Holiday planning so why should this not be the case for business; illness or loss essential items can have devastating effects,  not just for those away but equally for the businesses left behind.

It’s that time of year again, it may be cold and wet outside but we are well and truly into the “holiday” season. For many companies the next few months will present a difficult time as  key personnel take annual holiday. In the past, cover was provided by other staff members but as the majority of  manufacturers have had to reduce manning levels to survive the current economic downturn, this now means that such contingency options are often limited.  If illness or other unexpected events then prevent those people providing the cover from being at work  this can become  a major cause of disruption in critical areas. In the last few years some forward thinking manufacturers have taken the bold step of pre-arranging standby sub-contract machining capacity to cover this eventuality and thereby minimise such risk to production during this period. Monolution have been chosen by many of them to provide this short term support.

As this is also the time that companies undertake annual plant maintenance, move equipment or undertake site refurbishment, it could also be prudent to have a back up plan in case such work overruns. If your CNC machining capacity is suddenly reduced by an unexpected breakdown or if planned maintenance reveals the need for  additional  spare parts that are not immediately available then having an alternative source for high quality machining is a useful safeguard.

Talk to Monolution about our sub-contract machining services now,  so that when the time comes  you can relax & enjoy your holidays knowing you’re fully covered!

To be effective,  a mission statement must  be a declaration of intent,  provide direction and identity; in short a focus for all those associated with the enterprise. It should serve as a reminder to  directors &  staff, a reference for customers and suppliers and a  warning to your competitors.

Not only should the mission statement clearly identify what  the organisation exists to do  but also why and for whom.  Setting out clear objectives, establishing priorities and defining the philosophy that underpins the whole organisation are key factors that define the scope and application of your business.

We  believe our mission statement meets these objectives,  but judge for yourselves:-

Monolution exists to provide a bespoke service to customers that need a quality driven, responsive partner who can deliver effective solutions to meet even their most challenging machining requirements. Monolution is determined to become the supplier of choice for Aerospace, Automotive and other precision components, tooling, prototypes and development models through continual improvement and by :-

• Utilizing the latest technologies and cutting techniques in highly imaginative and efficient ways.
• Being customer facing with total quality assurance through closely managed processes and well defined procedures.
• Being flexible in our approach yet disciplined in our application.
• Demonstrating reliability and consistent on-time delivery.
• Being a future focussed, well managed, secure and sustainable business

A dynamic business  should not consider the ” Mission Statement”  to be immutable,  but should review and adjusted it, as with any other element of the organisation, as it grows and develops  -  so watch this space!

Very few, if any enlightened Buyers or Purchase Manager’s are likely to place orders solely on price, especially in the competitive area of sub-contract machining. Quality, lead time and confidence in the supplier are all significant considerations that influence that all important decision.

However, sometimes those same purchasers can be tempted to turn away from the existing supply chain when a new suppliers is apparently able to undercut those established sources. It is then that the hidden benefits of a true “preferred supplier” need to be evaluated and an indirect saving associated to this. An equivalent amount should then be added as an additional cost from the new supplier to give a truly accurate price comparison.

Identifying these benefits and apportioning a realistic value to them is the key to achieving a genuine like for like cost analysis. Depending on the relationship there can be many area’s to consider but three primary sources normally exist comprising, administration, support & reliance.

Administration; simplified enquiry and order placement, reduced documentation and correspondence with established lines of communication and multiple points of contact.

Support; an existing supplier will need far less, having already established proven technical ability, quality standards and a clear understanding of the contractors process and procedure needs.

Reliance; a reliable supplier can provide the means to lower the working capital needed by reducing or eliminating stock holdings; improve cash flow by shortening the gap between payments and receipts and contribute positively to product development and ongoing cost reductions.

The actual amount this can be worth will vary by the type and complexity of the work undertaken but is not insignificant and can be calculated with a little effort.

If you measure the real value, not just the piece part price, when assessing your suppliers quotations then Monolution feel sure that not only are they competitive but you may actually find they prove to be cheaper overall despite perhaps the slightly higher headline price.

You don’t have to look far for evidence of this.  Recruitment agencies are awash with vacancies for Design staff, Manufacturing engineers, CNC Machinists and Quality Managers.  At high profile Job Fairs up and down the country you’ll find many significant Tier 1 & Tier 2 companies listed   amongst the recruiters taking part and seeking additional key workers. Stocks of new and good quality used equipment are at a very low levels following diminished demand over the last few years leading to extended delivery times on more specialised equipment.

The need to bring new products to market quickly is never greater than when the economy and markets are at their weakest but are then so often compromised by a lack of the necessary resources.

 If you are one of those companies with a growing order book, perhaps seeking additional staff or needing to invest in additional equipment, who must avoid putting this new business at risk through lengthening lead times, then Monolution can help.  Not only do we provide a full range of competitive sub contract CNC machining but, as we are highly reactive we are an ideal source for short term additional capacity, perhaps whilst bringing new plant or machining facilities on line or in the event of key machine breakdowns. We can also be an alternative resource available whilst recruiting, covering for absenteeism due to illness and holidays or simply when demanding deadlines need to be met.

We all need a little help sometimes, and it’s nice to know there’s someone to turn to when it’s necessary.

The answer cannot solely be the use of the latest multi axis machining technology, although Monolution have continued to invest in additional machines despite the difficult economic climate and vagaries of the UK manufacturing sectors, or indeed its ability to work directly and immediately from CAD data models. The secret as they say, is not what you’ve got but in how you use it!

Never has the KIS ( Keep It Simple ) principle been applied with greater  effect  with  every aspect of the machining processes  stripped back  to the most fundamental  requirements of presenting the cutting tool  to  material in the most advantageous way so as to maximise the efficiency of the material removal.  The contributing factors; work holding , cutting tool and machine spindle each play a significant role in performance,  accuracy  and cost  and all  can be optimised  with a time and the relevant investment . Within the primary manufacturing industries with repeating components this is the goal of the production or manufacturing engineer’s who developed and refine the processes on an ongoing basis and over time. However the Sub contractor market often has only the one opportunity  and must therefore get it  right,  first time,  on time,  every time.

So, how do we do it so consistently? Well we have developed some imaginative approaches to minimise work holding requirements, setting-up time and cutting tool selection to achieve optimum performance at the tool tip.  Couple this with a lean & flexible scheduling system that extensively “nests” complimentary parts or operations together in some unique parallel processing techniques and you have a highly reactive, efficient and reliable manufacturing environment.

With  active,  real time  monitoring and  a quality focussed management  system  it is perhaps  not so surprising  that  we continue to meet  or surpass the  demanding expectations  of our many satisfied customers.
But let’s keep that to ourselves, it’ll be our little secret!