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Meet our CAD/ CAM specialist

Ian Barrett, CAD and Engineering Specialist, tells us more about his role and how the SAM Project can help SMEs embrace CAD and CAM technologies.

Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) technologies were developed in the ‘80s and are now widespread across the industry, helping improve practicality and productivity for businesses the world-over.

Throughout my career, all of my roles have involved some form of design, especially during the early days of CAD adoption, from developing consumer products to large scale heavy engineering projects. I also have a vast knowledge of prototype manufacture (both rapid prototyping and small batch production) and testing.

This has helped me establish an excellent working relationship with customers and colleagues who – as a result – trust my judgement when it comes to all things CAD and engineering. A business’ needs must be managed, and I take responsibility to gather the relevant information, design or fit a solution to overcome any issues, put them in place and ensure the manufacturer is satisfied and that – more importantly – the problem has been solved, and not just with a ‘sticking plaster’, so to speak.

Due to my experience, knowledge and role, I am actively involved in a whole host of engineering projects, carrying out design layout, concept and prototype design, design for manufacture studies, drawing creation, FEA studies and providing additional information to customers who may require support that is over and above the usual role of a design engineer.

The SAM Project, our Prototype Factory, at The Industry Centre, and most importantly, our staff, allow the region’s manufacturers to experience and benefit from technology and knowledge that – in usual circumstances – would be difficult to access. Especially for small businesses. It’s also all under one roof and on their doorstep, at absolutely no cost to their business.

Recent success stories include using CAD to help an SME manufacturer develop a transparent, bullet-proof security barrier for the armed forces. Not only did we design the modular framework and supporting accessories, we also provided a scale prototype allowing the customer to have meaningful conversations with not just the MOD but also their finance and funding bodies.

Another saw us work with a family-owned beauty salon which – prior to tapping into our support – had absolutely no manufacturing or design experience. We helped them develop their idea for an easy-to-clean, portable, mobile hygiene screen and brought the idea to life by creating a fully functioning prototype. They are now looking at selling the product across the globe.

So, if you’re an SME manufacturer in the North East wondering how you could benefit from adopting CAD, need to provide CAD data and are not sure the best route to do it, or get the most out of your current CAD installations, why not pay us a visit at the University of Sunderland and see for yourself how our support could benefit your business?

Hundreds of firms have secured grant funding from SAM, could you be next?

Since 2018, the SAM Project has helped over 200 North East businesses become more productive and sustainable by supporting projects that enhance products, processes and technology.

Central to this success has been its incredibly popular Grant Funding scheme, providing matched-funding grants of up to £50,000* for manufacturing projects that support the growth of new products and processes.

This encompasses funding towards new to firm production technology; new product validation (tests/ consultancy); process improvement capital investment; structure to support research and development implementation; external consultancy on a time limited basis linked to a manufacturing/ production project and other product and process development costs.

During the first phase of the SAM Project, spanning 2018 – 2020, this saw the Project distribute over £1million in matched-funding grants, helping add £41.7 million in GVA to the North East businesses that engaged with the programme, creating 290 direct jobs and leading to a 30.1% rise in sales.

And the team at SAM are confident that, following its three year extension to 2023, it will have an even larger impact on the sector going forward, after it saw its grant pot double in size – by a further £1 million – and its technical team at the University of Sunderland continue to grow.

Speaking about the grant funding, Claire Darling-Cooper, compliance officer at the SAM Project, said: “The Grant Funding scheme proved incredibly popular with the region’s SME manufacturing base during phase one of the project, so we were delighted when we received confirmation that it had been extended for a further two years until 2023.

“Not only did it help create jobs, but it also helped safeguard many more and as we look to re-emerge from the pandemic, business support initiatives such as this will be key to ensuring the region’s manufacturers have all the tools they need to compete on the global stage and continue to innovate and grow.

The grants are restricted for small to medium sized (SME) business in the North East Local Enterprise (LEP) area – spanning Northumberland, County Durham and Tyne & Wear – and are also accompanied by 10-15 days’ worth of fully-funded technical support from the SAM Project’s team of eight manufacturing experts, who combined, boast over 250 years’ experience working across the industry in a number of senior roles.

Claire added: “We know how much of a leap of faith it can be when investing in new capital equipment, which is why we provide the technical expertise required to really understand the technology and all of its pros and cons, ensuring we help de-risk each and every investment we underpin.”

One such company to benefit from the SAM Project’s Capital Grant scheme is Vixen Surface Treatments Ltd, a market-leading manufacturer of industrial wet and dry blast cleaning cabinets.

After engaging with the SAM Project, the company was able to receive an in-depth demonstration of how 3D CAD visualisation software could help improve both its design and sales processes, as well as securing the funding required to invest in state-of-the-art software from Solidworks to implement the technology into its business model.

Aidan Mallon, managing director of Vixen Surface Treatments, said: “The first project we completed after the investment saw us test the Solidworks software on a live project that we won. It was a €500,000 export order from a German aerospace company and I genuinely believe we wouldn’t have won that contract without including it in our offer. It really adds credibility and professionalism to our proposals.

“As a manufacturer you must explore every avenue possible to grow your business, be it investing in new equipment or tapping into expertise and funding – and business support from organisations such as SAM is vital to helping SMEs move forward.

“We’d just extended our factory prior to approaching SAM and wanted to move into Solidworks. The grant helped us secure the funding needed to do that and accelerated our growth, helping us gain a competitive advantage by massively increasing the quality of service we’re able to offer clients.”

Another company to benefit from the grant scheme is Chester-le-Street architectural metalwork specialist, Steelcraft Ltd. Since engaging with the SAM Project and securing a five-figure funding grant, the company has expanded its product offering and launched a new brand, Forjj, allowing it to diversify and sell its products directly to consumers across the globe.

“The team at SAM were absolutely amazing,” Liam Armstrong, operations manager at Steelcraft said. “Prior to engaging with them, our factory hadn’t changed in 20 years and we were struggling to see how we could scale up our operations while keeping costs and disruption at an absolute minimum.

“Using simulation software, they were able to create an identical, computerised model of our workshop and, working closely with our production manager, identify which machines and processes could be altered and moved to make space for the new machinery and improved workflow.

“We’d never have even thought about using digital twin software to visualise and improve our shop floor and – as a family-business – we could never have accessed something like this without the support of SAM.”

The grants are accessible by all manufacturing SMEs, who can also still engage separately in a technical project with SAM (this can often support or identify the need for a grant application or helps to specify their precise needs and focus on the benefit and returns). The grant award is 25% matched funding available to those in Tyne & Wear and Northumberland and 35% for those in County Durham. The grants can also be used to support the purchase of second-hand equipment, as well as brand new machinery kit and software, and can even be used for specialist services or testing needs that may be holding a company back.

Claire added: “Vixen and Steelcraft are just two of scores of success stories we’ve recorded through the Project’s journey so far and are evident of the impact this support can have.

“Not only do the grants help break down the barriers to investing in new technology but they also help eliminate other financial inhibitors to driving strategic development of both product and process.

“The only drawback for us is that we only have £1 million to give away. While it may sound like a lot, the first phase of the SAM Project proved so popular that the grant pot was empty well in advance of the project’s end date, therefore we’d recommend any manufacturer reading this who thinks they may be eligible to get in touch with us and find out more.”

Interested in finding out more about the SAM Capital Grant scheme? Visit: https://samprojectuos.co.uk/grant-support-helps-sustain-growth-for-vixen/ or email: sam.project@sunderland.ac.uk

North East manufacturers urged to tap into support before it’s too late

Manufacturers across the North East are being urged to tap into grant funding and fully-funded technical support to help their businesses innovate and grow.

The Sustainable Advanced Manufacturing Project (SAM) was launched in 2018 to help businesses become more productive and sustainable by supporting projects that enhance their products, processes and technology.

Since then, the programme – which was originally due to end in December 2020 – has proved a huge success, providing over £1 million in matched-funding, as well as practical and research support to over 200 SMEs across the region and is set to continue supporting the sector after securing a further £6 million, taking it to June 2023.

The pioneering initiative was originally part-funded by ERDF – with a £2.6m commitment – and the University of Sunderland and industry, which invested £2.5m, and is aimed solely at small and medium sized manufacturers (under 250 employees) based in the North East LEP area, with an annual turnover of less than €50m (£45m approx.)

The project offers a range of assistance – tapping into significant academic resources, a team of industrial specialists and five distinct factories with more than £1m worth of equipment – to offer both practical and research support, ensuring businesses can access a knowledge bank comprising some of the industry’s brightest brains and most advanced technology. This extension has also seen SAM’s Technical Research and Development team grow, to offer even greater specialist industry support to companies.

Roger O’Brien, Research and Technical Lead at the SAM Project, said: “The first phase of the SAM Project was a huge success and we were delighted when we heard that the project was to be extended. Over the last two years, we’ve provided funding and support to hundreds of businesses and have witnessed first-hand the impact this has had, from safeguarding and creating jobs to transforming entire production lines.

“Since the pandemic hit, the impact it has had on the nation’s manufacturing sector has been catastrophic. However, it has also provided opportunities such as re-shoring and bringing back in-house previously sub-contracted works, as well as business diversification. Now, more than ever, manufacturers need our support and this funding boost will go a long way to helping many of the region’s SMEs adapt and grow as we look to re-emerge from this crisis and keep Britain’s economy moving.”

In phase one, the SAM Project provided matched-funded grants of up to £50,000 to SMEs across the North East LEP area for capital, product validation, equipment and other financial inhibitors to drive the strategic development of both product and process. This has continued in phase two, with an additional £1 million being put into the grant pot, together with some tweaks to the intervention rates (now at 25% in Tyne and Wear and Northumberland and 35% in County Durham).

An independent report commissioned to explore the impact of phase one also revealed that the programme helped create 270 jobs and added over £47 million in gross value to the regional economy. It was also revealed that SAM’s impact on innovation and new product development meant that the average TRL (Technology Readiness Level) – the scale on how new products are measured as being close to market launch – was a staggering 3.9 steps, with some clients jumping from Stage 2 up to Stage 9 due to SAM support.

“Our fully-funded technical advice and support is what really makes the SAM Project stand out from your traditional business support schemes,” Roger adds. “While there are many other grant funds out there to help businesses grow, there are very few – if any – which offer the intensive, personalised technical support that we do.

“Combined, our nine experts boast over 250 years’ experience working for an array of businesses, from blue-chip manufacturers to start-ups, with each of them specialising in their own individual disciplines, from additive manufacturing to automation and robotics, AR/ VR, electronics and process improvement, to name just a few.”

Roger concluded: “If you’re an SME manufacturer, then the engineers, researchers, grants and access to capital are here to help you adapt to the inevitable process changes facing us post-pandemic and to help take your business to the next level.

“Programmes like this are pivotal to ensuring the North East continues to lead the way in product, process and technology innovation – and we can’t stress enough how important it is that manufacturers get on board.

“There is only a set amount of money and technical support available, therefore – following the huge success of phase one – early registration is highly recommended.”

For more information on the Sustainable Advanced Manufacturing (SAM) Project, visit: https://samprojectuos.co.uk/

How tech can plug the manufacturing skills gap

Much has been made of the skills gap in the UK manufacturing industry in recent years and there are a number of factors contributing to this, including a lack of investment in new technology.

The manufacturing industry is heavily influenced by evolving technologies and new techniques are constantly helping to improve processes and the quality of end-products. There’s also no hiding from the increasing amount of computerisation involved in production processes, as well as the need for bespoke software solutions to meet growing demand, utilise different materials and manage workload.

As someone who has spent over 30 years’ in the industry, I’ve witnessed this first-hand. After working at one of the earliest adopters of industrial robots in the UK, Tallent Engineering (now Gestamp), I have seen the first robots they installed in the early 1980s grow to a robot population of over 1,200 at its Aycliffe site, with the pioneering technology helping bring continued success to the company and making it more competitive on the global stage.

Fast-forward 30 years and we have seen many more of the region’s manufacturers invest in emerging and mature technologies, such as AR/VR, which has been embraced by the likes of Caterpillar in Peterlee. However, technology advancement isn’t unique to large companies, despite the many pre-conceptions of such technologies being too expensive. In fact, this couldn’t be further from the truth.

Recently, we have worked with scores of North East SMEs to help them embrace new technologies, including companies such as Kail &Co, Heliguy, and AR Controls. Additive manufacturing in particular is increasingly competing with traditional manufacturing techniques even outside of prototyping and is a fundamental part of the 4th Industrial Revolution.

This is why, when reading the latest ‘Addressing skills and labour shortages post-Brexit’ report by the CIPD, I was surprised to see that only 9% of UK businesses plan to invest in technology as a way of addressing skill or labour shortages over the coming years. Technology is such a key driver within industry, which is why it’s now as important as ever to support businesses and employers to increase the adoption of new technology and support the skills development of staff.

Many SME manufactures are facing staff shortages and short-term interventions are needed in the way of quality business support and funding to overcome this crisis, making the investment in skills and technology more manageable and paving the way for long-term success. This support is exactly what the Sustainable Advanced Manufacturing (SAM) Project is here to provide, by helping SME manufacturers to innovate, grow and diversify.

Backed by ERDF, the Northern Powerhouse Initiative and the University of Sunderland, the SAM Project has a team of dedicated technical experts who work alongside the region’s SME manufacturers to support the implementation of product and process development, as well as the introduction of technology, at absolutely no cost to businesses. We also have matched-funding grants to help make the investment in new technology as affordable as possible.

Over the past few years, I have seen with my own eyes the many benefits that investing in technology can have on SMEs through some of the incredible projects we have been a part of, helping manufacturers embrace new technologies such as robotics, automation, design software, 3D printing and augmented and virtual reality. It’s technologies like these that open new doors for businesses and provide their employees with the capability to build upon their skills and ensure they are employable for years to come.

One such business that we were proud to support is specialist metal fabricators, Almet, who we helped explore the use of robotic welding technology through live demonstrations, showcasing to the team what they could achieve with this type of machinery based upon their specific needs. The Washington-based company has now increased its factory size by 12,000 sq ft and is investing in the technology itself to enhance processes. Not only did this safeguard jobs, but it will also create a number of highly skilled roles.

Another company we supported was precision engineering specialist, Ashgarth Engineering, providing funding to help with the purchase of a 3 axis vertical machining centre with a 4^th axis attachment. This allowed the company to branch out into new markets and offer their current clients additional processes, leading to an increase in turnover and the creation of jobs.

However, tackling the skills and labour shortages post-Brexit and post-pandemic will take time and will also need to filter down to education, increasing awareness in schools about careers in manufacturing and increasing the number of manufacturing apprenticeships to help bridge the skills gap.

The manufacturing industry can provide employees with limitless potential to grow and learn as technology continues to advance. After all, just because someone lacks a certain skill, or the knowledge to operate new machinery, doesn’t mean they won’t pick it up quickly. If you have the willingness to learn and explore the opportunities in front of you, the skills shortage can be reduced, and your business can thrive.

For the SAM Project, we will continue to encourage the regions SME manufacturers to explore the support on offer and get in touch to find out how we can help. Our objective has always been the same, to build resilience among the region’s SME manufacturers, increase productivity and help not only safeguard, but also create jobs for the generations to follow.

Breaking down the barriers to robotics

Neil Taylor, Automation & Robotics Specialist, explains why embracing robotics is key to ensuring SME manufacturers remain competitive.

When I was first appointed Robotics Programmer at the then Tallent Engineering, back in the early 1980s, the technology was often seen as somewhat of a threat to jobs, and a far-fetched concept by many others.

Based out of Aycliffe Business Park, in County Durham, Tallent Engineering, now Gestamp, was one of the first non-OEMs (original equipment manufacturers) to embrace robotics, and as a result grew from being a multi-product manufacturer with just a single site, which had a handful of robots, into one of the world’s leading automotive Tier One suppliers, specialising in specifically in chassis and suspension products in just a matter of years.

Having started out as a welder, my role as robotics programmer initially saw the company invest in 10 robots, which at that time, none of the staff had even heard of and saw productivity increase significantly, helping us ramp up the output of parts we were producing for the Ford Sierra, improving quality and drastically reducing lead times.

Fast-forward 40 years and Gestamp now has over 1,200 robots operating at its Newton Aycliffe site alone, (the largest none OEM population of robots on one site in Europe), with tens of thousands more in operation across the globe – ranging from robotic welding, both MIG & Spot, machine tending, bushing, inspection and palletising. Robots have been key to that growth and success, along with challenging the norms of traditional production.

However, despite the rapid advancement of robotic technology over the last few decades and the heightened adoption of automated processes by the majority of automotive OEMs and Tier One suppliers, many manufacturing SMEs are still yet to harness and embrace the potential of robotics within their operations, often believing them to be out of reach price wise or technologically challenging.

For many, their reservations are predisposed to thinking that they would unable to afford the technology, that the costs will far outweigh the business benefits, or that the skills required are out of reach, however this couldn’t be further from the truth in the majority of cases, especially with the emergence of technology such as collaborative robots (cobots).

Here at the ERDF-funded Sustainable Advanced Manufacturing (SAM) Project, we have a team of technical experts working shoulder-to-shoulder with the region’s SME manufacturers to help break down the barriers to embracing new technology and improving processes.

One such company to benefit from the support is Almet. The Washington-based specialist fabrication business is set to increase its factory size by 12,000 sq ft over the coming months as it invests in robotic technology in a bid to enhance its processes. Working with the team at SAM, Almet was able to explore how the use of robotic welding technology could benefit its business, as well as tapping into the funding required to support the purchase of its new equipment. It was also able to weigh up the various alternative and benefits of deploying either cobots or traditional industrial robots based upon their specific applications, needs, volumes and repeat orders.

Another success story to arise from SAM’s fully-funded support is Pilgrim Spirit. Based in Alnwick, the premium brand gin producer was able to receive an in-person proof of concept demonstration of state-of-the-art cobot technology. This demonstrated that manual handling errors could be significantly reduced and even eliminated by using an automate process, whilst allowing them to increase productivity and utilise what would otherwise be downtime by extending operations to a 24 hour basis. This is subsequently to be deployed in their facilities following on from the engagement with the SAM Project. Initially they had paid a visit to our home at the University of Sunderland’s Industry Centre to find out more about 3D printing, but following on from this and seeing the potential after paying a visit to our six specialist factory areas, which have seen over £1m invested in new technology, they broadened their thinking and looked at how automation could benefit them.

Boasting everything from robotic welding cells to palletising robotics, collaborative robots, sensors and automation, latest virtual/augmented reality technology, sophisticated 3D printers, including metal printers, plus much more, the factories provide the region’s SMEs with an opportunity to test out advancements in their sector prior to making substantial financial investment and has been well received by the industry since its launch in 2018.

Not only do these facilities allow companies to fully-understand how the technology works and how it is relevant but, similar to Almet, it also allows the companies to access matched-funding grants to support the purchase and installation of these technologies for their business.

Recent independent reports show that companies who engaged in the first phase of the SAM Project reported significant growth and improvements, including such things as improved layout, increased productivity, being more competitive through adoption of latest technology and increases in quality.

Companies such as Almet and Pilgrim Spirit have seen business skyrocket, creating new jobs and winning numerous new clients or opening up new markets as a result of technology adoption, and specially robotics and automation.

Yet, despite a recent report by the British Automation & Robotics Association (BARA) revealing that UK industrial robot sales were up 7.5% in 2020 on the previous year, there are still scores of manufacturing SMEs across the North East that are yet to have their eyes opened to the huge, somewhat untapped potential of robotic technology and the support on offer to help them steal a lead on the competition.

While it’s pleasing and reassuring to see sales of industrial robotics increase, we must continue encouraging more of the region’s manufacturers, particularly our SMEs, to explore all of the avenues of support available to them as we look to step out from the pandemic on the strongest possible footing and ensure UK manufacturing becomes more and continues to remain competitive on the global stage.

It is significant to note that the UK lags behind other major manufacturing economies in its use of robotics, so not only can SMEs increase local market share, but they can also explore wider markets and bigger potential that have previously been untapped.

Not only do robotics help significantly improve productivity, but they can also lead to reduced operating costs, improved quality and less material waste and in order to further build on this heightened demand for industrial automation, we must continue to champion projects such as SAM.

So, if you’re a small to medium sized manufacturer, or even a business looking to begin manufacturing, talk to SAM today to find out how the support could benefit your business.

It could be just the push you need to step your business up a gear, be that via automation or any of the other technologies or product and process design support on offer from within the SAM team…

Manufacturers urged to ‘think local’

A TEAM of industry experts is urging regional manufacturers to prioritise localising supply chains, to minimise the impact of future crises on the sector.

The Sustainable Advanced Manufacturing Project, a £10.9million initiative set up to provide expert advice and funding to North East SME manufacturers, issued the rallying call after witnessing first-hand how travel restrictions have affected the sector over recent months.

When national lockdowns were imposed in March last year due to the pandemic, entire supply chains were brought to a halt almost overnight, highlighting the extreme fragility of extended global supply chains, as firms the world-over were unable to import key components and materials.

Scores of small to medium sized manufacturers from across the North East have since approached the team at SAM – comprising academics from University of Sunderland and industry leading experts – for advice on securing and safeguarding their supply chains, as they look to minimise the impact of future crises.

Ken Teears, Project Manager of the SAM Project, said: “British manufacturing has been dealt blow after blow by the pandemic and establishing sustainable, localised supply chains is key to safeguarding the industry’s future.

“This was not only a challenge for the large Original Equipment Manufacturers (OEMs), SME manufacturers were also left high and dry as suppliers in mainland Europe closed temporarily and imports ceased.

“The SAM Project was able to advise companies on how they could bring production in-house and identify the manufacturing equipment required to do so.

“Companies saw that, while the unit price of making components in-house was slightly higher, the reduced risk, increased resilience and ability for staff to move onto this equipment if supply chains were disrupted again, meant they were good investments to make.

“Over the past 40 years we have seen a huge shift in the number of western manufacturers setting up facilities and sourcing parts from suppliers in low-wage economies, while failing to heed the advice of the many industry-experts and academics urging companies to establish more localised, sustainable supply chains.

“While there is no hiding from the fact that the production of materials and parts overseas can be – at times – significantly cheaper for manufacturers, the pandemic acted as a stark reminder that the ever-growing trend of manufacturers relying upon imports can also be hugely damaging to the industry’s supply chains.

“Jaguar Land Rover was a great example of this. When Chinese factories and ports were forced to close in February last year due to the pandemic, the automotive giant’s global supply chain almost ground to a halt and the company made headlines the world-over after being forced to fly-in vital components via suitcases.”

Another example was the UK’s reliance upon imported PPE, the majority of which failed to meet the standards set by Public Health England (PHE) and forced a valiant effort from UK manufacturers to diversify and begin producing PPE of their own to support the fight against the virus.

Within weeks, millions of items of PPE were produced by UK manufacturers – many of which were from the North East – meeting the highest of industry standards and ensuring the safety of our key workers.

As well as quality and economic benefits, the reshoring of manufacturing and localising of supply chains also has huge environmental advantages, helping companies slash their carbon footprint and support the UK’s fight to cap greenhouse emissions.

“Many materials and parts are transported halfway around the world before the final product is even sold.” Teears said. “By sourcing goods locally, we can effectively eradicate the need for unnecessary transport, helping firms reduce their carbon footprint and providing a huge shot in the arm to their local economies.”

The SAM Project was launched in 2018 in a bid to help businesses become more productive and sustainable by supporting projects that enhance their products, processes and technology.

Since then, the programme – which was due to end in December 2020 – has proved a huge success, providing £800,000 in matched-funding – as well as practical and research support to over 200 SMEs across the region – and is set to continue supporting the sector after securing a further £6 million, taking it to June 2023.

“If we can encourage more manufacturers to source parts locally, bringing production back to the North East that was previously outsourced and/or re-shore a larger proportion of their components, then this will prove a huge boost to the region and the resilience of the sector going forward,” Teears added.

“Since the outbreak of the pandemic, manufacturers of all kinds have contacted us for support and we have witnessed lots of companies looking to think local and make their supply chains more sustainable.

“If we can be certain of one thing as we look to 2021, it’s that there will undoubtedly be more challenges ahead for the sector as we look to bounce back from the pandemic and adjust to the new trading conditions brought about by Brexit.

“However it’s important to remember that support is available for those affected, from both the SAM Project and other programmes in the region, whom we work closely with, and we’d urge any company seeking advice and guidance to contact us for support and guidance.”

For more information on the SAM Project, visit: https://samprojectuos.co.uk/

Grant support helps sustain growth for Vixen

A NORTH East manufacturer of industrial cleaning machinery and equipment has revealed how a business support programme helped it through the pandemic and prepare for life post-Coronavirus.

Founded in 1990 by managing director Aidan Mallon, Thornaby-based Vixen Surface Treatments is a market leader in the production of wet and dry blast cleaning cabinets, degreasing machines and phosphating equipment.

Manufacturing both off-the-shelf and bespoke machinery, the company exports 40% of its products overseas to customers in the nuclear, engineering, healthcare, automotive and aerospace industries, meaning it is often required to maintain close and constant dialogue with clients.

Thanks to a capital expenditure grant obtained last year from the Sustainable Advanced Manufacturing (SAM) Project – which offers a range of support to the region’s SME manufacturing businesses – Aidan and the team were able to mitigate the impact of social distancing and travel bans throughout the pandemic, by purchasing state-of-the-art 3D CAD visualisation software.

The installation of ‘Solidworks’ software means Vixen is able to provide 3D demonstrations of its products to clients, allowing them to visualise how products will look and work once complete.

Aidan said: “As a manufacturer you must explore every avenue possible to grow your business, be it investing in new equipment or tapping into expertise and funding – and business support from organisations such as SAM is vital to helping SMEs move forward.

Vixen began producing 3D virtualisations just under a year ago and it has already enabled the company to secure a major export order from a German aerospace business, as well as helping keep its order book filled during the pandemic, which brought manufacturing supply chains to a halt across the globe.

“The first project we completed after the investment saw us test the Solidworks software on a live project that we won,” he added. “It was a €500,000 export order from a German aerospace company and I genuinely believe we wouldn’t have won that contract without including it in our offer. It really adds credibility and professionalism to our proposals.

“It also helped us share up-to date designs and updates with clients during the pandemic, meaning we could still fulfil orders despite travel bans. That’s not to say we weren’t impacted by the pandemic – as we were functioning with just 25% of our workforce at one stage – but it certainly helped us to continue operating and servicing clients.

“We’re now have almost everyone back at work and the continuity of interest means our order book remains heavy. Now, looking to the future, we’re confident that we can continue building on this.”

SAM offers four key support functions to businesses that are gearing up to grow, including access to technical expertise, with industrial specialists using their skill and expertise to guide businesses through the process of understanding and implementing technology; R&D, with a team of researchers able to support with the development of new products and processes; factories and facilities, including access to £1m of industry-leading advanced technology and equipment; and its grants scheme, that offers financial assistance to businesses that qualify.

Ken Teears, project manager at SAM, said: “Vixen Surface Technologies is a fine example of how visualisation through 3D technologies such as Computer Aided Design (CAD) and Computer Aided Manufacture (CAM)can help businesses innovate and grow, even during the most challenging of conditions.

“Millions of manufacturers across the world are reeling from this crisis and wondering how they can improve business continuity strategies in the event of such disasters going forward. Technologies such as Solidworks and other CAD, CAM that can also be pulled into Augmented Reality (AR) and Virtual Reality (VR) will play a huge role in helping businesses minimise downtime in the future. It’s been a pleasure working with Aidan and the team and we’re excited to see what the future holds for them.”

Image shows: Aidan Mallon, managing director of Thornaby-based Vixen Surface Treatments.

DLAW expands with SAM help

A NORTH EAST manufacturer of industrial heating units for the agriculture sector is celebrating after securing its largest contract to date.

DLAW Contractors, based at Port of Sunderland, has created four new jobs as a direct result of the six-figure contract win, which will see it manufacture, supply and install a 6.2 megawatt output grain drying unit for a working farm in Northumberland.

The grain drying unit – which will be powered by two geo-thermal ground-source heat pumps – was designed and procured by renewable energy specialist Calibrate Energy Engineering on behalf of the farm. The project will drastically reduce its reliance on fossil fuels and significantly reduce its carbon footprint when fully operational.

The contract win marks the 17^th industrial heating unit to roll-off the DLAW production line since the company opened its manufacturing facility at the port in April 2019 and has seen the firm recruit four more staff – from accounts to coded welders – to help ease its ever-growing workload.

Dale Barry, co-founder and managing director at DLAW, said: “This is a huge win for us and we are absolutely delighted to be in a position where we can continue investing in the business and create opportunities for local people, especially during a period of such economic uncertainty.

“Over the past 18 months we’ve seen the business grow from a team of four to a team of 12 full-time members of staff operating from our own, dedicated manufacturing facility, and we couldn’t be happier with how the company has progressed.

“As well as manufacturing our geothermal heating units, we also have a contract to manufacture solar-powered containerised, transportable water treatment systems for Pure Water International. The units provide a self-sufficient and sustainable way for hard to reach communities across the globe to access clean drinking water and we’re confident both sides of the business will continue to grow as we look to the future.”

Shane McDonald, director of Calibrate Energy Engineering, added: “We awarded the contract of principal contractor to DLAW based on its understanding of the product and expertise in the manufacturing sector, which gave us confidence to move forward with the project and we are delighted to be working with them”.

DLAW secured the contract after tapping into support from the Sustainable Advanced Manufacturing (SAM) Project, a £10.9million business support programme led by the University of Sunderland and backed by the European Regional Development Fund (ERDF).

The support helped DLAW not only identify the machinery required to improve its manufacturing process but also provided it with the funding to help with the purchase of a new 8×4 CNC Plasma Cutter machine.

“The support we’ve received from SAM has been fantastic,” Dale added. “Not only has it helped us invest in new machinery, but it has also helped us improve our processes and ensure we are running as lean an operation as possible.

“Without the new CNC Plasma machine we would have struggled to take on a project of this size and I couldn’t recommend the project enough to any manufacturing business looking to futureproof their business and continue growing post-pandemic.”

Ken Teears, project manager at SAM, said: “The SAM Project was set up to provide innovative SME manufacturers across the North East with the tools and capital required to help them push the boundaries of their respective industries and DLAW is a perfect example of this.

“As a start-up business, the company has been able to adapt quicker than most to changes in its key markets and this is evident by its latest success which has seen the firm punch well above its weight and position it as a key challenger in the supply of industrial heating units. We are delighted to have been able to support the company and would like to wish them all the best for the future.”

Turnmill rejigs as orders soar

A SUNDERLAND-based engineering firm has expanded its presence in the city after investing in new premises and machinery during the pandemic

Turnmill Engineering, which is based at Washington Business Centre, works with businesses and individuals to help bring new products to market and improve production processes.

Specialising in the production of consumables, jigs and fixtures and machine components, the company was founded in 2018 by three industry experts boasting over 100 years’ experience between them and – boosted by an uplift in orders during the pandemic – is currently on track to record its best year to date.

The expansion, which has seen the firm increase its footprint three-fold, coincides with an investment in new machinery, including three Mazak CNC lathes machines, which will help the company achieve its target of increasing output by 50% over the coming months as it looks to ramp up production.

Andrew Howe, co-founder and operations director, said: “We try to concentrate on jigs, fixtures and production line improvements but if you were to take one look at our order book then you’d soon see just how much of a wide range of projects we work across.

“We started out in 2018 by completing a handful of projects for clients primarily in the automotive sector however since then – literally by word of mouth – we have diversified and established ourselves in several key sectors including pharmaceuticals, motorsport and construction.”

Turnmill Engineering has grown by 30% year-on-year since its launch however its busiest period to date proved to be while the UK was placed in lockdown during the Covid-19 pandemic.

“We welcomed on board a number of new customers during the pandemic and this was mainly due to our production breakdown and line improvement service,” Andrew added.

“With manufacturers the world over forced to adhere to strict social distancing measures, companies began exploring new ways to reduce production costs and we have been fortunate in the fact that we’ve been able to help through the provision of new fixtures, jigs and product development and hopefully we can continue building on that momentum post-covid.”

Turnmill moved to Washington Business Centre after being introduced to the office space by Sunderland City Council’s business investment team and being impressed by its flexibility and its ability to accommodate its future growth plans, which will see the company continue adding to its headcount over the next 12 months.

Andrew said: “What really impressed us about Washington Business Centre was the flexibility it offered us to grow. Since moving to the centre two and a half years ago, we’ve already expanded three times into larger units which has allowed us to continue scaling while causing minimum disruption to the business.

“Another advantage was its location, as it is situated ideally on the Nissan commuter belt. The North East is home to one of the largest automotive clusters in Europe and to be right at the beating heart of this has proven ideal for us as a company and has played a key role in helping us grow.

“We now have five members of staff and – following this latest move and the investment in new machinery – are looking to create a further two roles over the next 12 months, one of which will be an experienced engineer and one which will hopefully be at entry-level as we look to pass on our knowledge and know-how to the next generation, too.”

Turnmill’s investment in new machinery was also supported by the University of Sunderland’s Sustainable Advanced Manufacturing (SAM) Project, which provides matched-funding and business support to SME manufacturers across the North East LEP area and recently secured a £6 million extension taking the programme to 2023.

Ken Teears, project manager at SAM, said: “We were delighted to work with Andrew and the team at Turnmill to help identify new opportunities for growth and invest in the machinery required to take the business to the next level.

“The SAM Project was set up to support the implementation of product and process development in order to help the region’s SME manufacturers unlock their growth potential and Turnmill is yet another great example of this in action.”

Councillor Graeme Miller, leader of Sunderland City Council, said: “Washington Business Centre was launched to help SMEs scale and grow and to see Turnmill Engineering continuing to innovate and expand its presence at the business hub is a fantastic success story not only for the centre but for the city as a whole and I think I speak for everyone at the Council when I say we’d like to wish them all the best for the future.”

North East firm turns weeks into days with new kit

A WEARSIDE engineering firm has trimmed weeks from delivery times, thanks to support from an elite team of manufacturing experts.

RDS Engineering is turning weeks into days and days into minutes, thanks to state-of-the-art scanning equipment, purchased with the assistance of the Sustainable Advanced Manufacturing (SAM) Project.

SAM, which offers a range of support to SME manufacturing businesses in the North East LEP area, also supported the Washington firm via a production planning and workflow management workshop, to help iron out any kinks in RDS Engineering’s internal processes.

RDS managing director, Rob Bone, backed the SAM Project as a vital weapon in the armoury to combat the impact of the COVID19 pandemic has had on manufacturing businesses.

“There are businesses that are going to need all the support available to them as we emerge from lockdown and begin the process of restoring normality,” said Rob. “Projects like SAM are essential to help firms, like ours, take that next step and begin operating on another level.

“We probably would not have been in a position to invest in the new scanning equipment if it weren’t for the support of the SAM Project. However, having done so, and gained new knowledge and understanding via the workshop, we have massively reduced our inspection timescale – in most cases turning weeks into days, which has been a huge manhours saving for the business.”

As well as the new scanner, SAM helped fund a new Hwacheon Vesta 1000+ vertical CNC machine, which has been installed at RDS Engineering’s Washingto HQ.

Established in 1991 by Rob and David Bone, RDS Engineering is an independent supplier of precision engineered components and tooling. Having established a reputation for rapid response and high-quality products to the oil and gas, automotive, aerospace and defence, medical and power generation sectors, the company has set its sights on the pharmaceutical and rail sectors as potential growth areas.

Jess Houston, RDS Engineering office manager, added: “Like every business, our immediate priority is making sure we emerge from the pandemic in a positive way and see no reason that, with the speed we can now accomplish inspection, we can’t expand into new sectors to win business.”

Ken Teears, project manager at SAM, said: “RDS Engineering is a prime example of a company operating successfully in a sector in which our region has particular traditional strengths. However, what sets them apart from many is the desire to drive forward progress and keep improving and streamlining its processes.

“As we look beyond the economic impact of the COVID19 pandemic, we want businesses to know that we are here for them – ready, willing and able to lend our support to the major effort required to get the UK economy back on its feet and moving in the right direction.”

As well as its comprehensive suite of support, the SAM Project also launched an adapted grant scheme to help SME manufacturers looking to pivot during the pandemic, and the organisation is urging eligible businesses to apply for funding before time runs out.

The fund provides support to companies that have had to diversify or adapt in order to stay in business and operational during and after COVID-19, with match funding grants of up to £10,000 available, as well as its normal funding stream to support businesses looking to diversify, or improve products and processes in order to grow.

Applications can be for new capital equipment or external expertise – excluding working capital, salaries, rent or rates – to help their company survive, adapt and sustain themselves through and after the crisis. Companies looking to innovate and grow are still encouraged to apply even if their capital investment is not specifically as a result of COVID-19.

This could include buying capital kit to help diversify income, bringing outsourced processes and parts manufacture in-house, such as re-shoring parts made overseas to safeguard supply chains, improvements required in manufacturing operations as a result of social distancing measures and government guidelines, or any manufacturing and production specific capital investment to help the company diversify, stay afloat or take advantage of changes in market conditions. Grants are offered at a 50% rate in County Durham and 40% rate in Tyne and Wear and Northumberland. The current grant fund ends in September 2020.

Sustainable Advanced Manufacturing is a collaboration between European Regional Development Fund (ERDF) and University of Sunderland, that was set up to support North East (LEP) SME manufacturers to explore and introduce new technology to improve their products or processes. It was funded with a £2.6m commitment from ERDF and £2.5m from the University of Sunderland, and is aimed solely at small and medium sized manufacturers (under 250 employees), with an annual turnover of less than €50m (£45m approx.)

To find out more about SAM, visit www.samprojectuos.co.uk or contact sam.project@sunderland.ac.uk

Images: Jess Houston, RDS Engineering office manager and Rob Bone, RDS Engineering managing director.