Living and breathing continuous improvement.

An unswerving commitment to quality…to making regular investments in advanced manufacturing technologies…and to delivering unrivalled customer service helps leading precision tooling and subcontract manufacturing specialist negotiate its way through the pandemic and set new, ambitious growth targets for the future.

GF Machining Solutions, the milling, EDM, laser and Additive Manufacturing machine tool manufacturer, and automation and tooling systems specialist, has recently supplied two, new high-performance Mikron machining centres with, advanced Heidenhain controls, to Mechlam Precision Tooling Ltd., – a leading precision mould tool, fixturing and subcontract manufacturing specialist based in Haydock.

The new MILL E 700U simultaneous 5-axis machine, equipped with an integrated 7-station automatic pallet changer (APC), and the new, large-capacity VCE 1200 Pro (3-axis) machining centre – both major additions to Mechlam’s already impressive machine tool line-up – were installed at the company’s 8,000sq. ft facility in Autumn 2021.

Over the last seven months (i.e., since their installation), the machines have been put through their paces machining a range of complex, high-precision parts, that includes complex and intricate components for mould tools, and that are made from an equally diverse range of materials i.e., aluminium alloys, tool steels, Stainless Steels, inconels, plastics etc.

A hallmark of Mechlam, and one that helps explain the company’s continuing success and the strong position it occupies in many of its customers’ supply chains, is the quality (accuracy and finish) of the parts and components it is able to machine: achieving exacting tolerances of +/- 5 microns and surface finishes down to Ra 0.2µm, are the rule – not the exception.

The two new Mikron machines have taken their place alongside a number of the company’s previously-acquired GF Machining Solutions’ machines that include both high-speed and universal Mikron 3-axis machining centres and AgieCharmilles advanced wire and die-sink EDM machines.

Explains Martin Atherton, Mechlam Precision Tooling’s owner and director:

“We have always invested in GF Machining Solutions’ technology.

“The machines are reliable, represent great value and deliver the accuracies, repeatability’s and surface finishes we require, and our customers demand.”

“The powerful, large capacity VCE1200 Pro, with its 18kW/16,000rpm spindle has increased our machining capacity and enables us to process large mould tool parts and precision components: its large worktable (1220mm x 620mm) means we can also comfortably machine multiple smaller components, using innovative and productivity-boosting fixtures, in a single set up too.”

The investment in the MILL E 700U simultaneous 5-axis machining centre with an integrated pallet changer reflects a discernable trend that, over the last few years, has seen Mechlam acquire multi-tasking machine tools.

Continues Martin Atherton:

“Although the company’s focus, initially, was on the mould tool and die sector we have, in recent years, diversified and expanded our operations so that now we also provide a high-quality subcontract machining service to customers operating in the automotive, medical, aerospace, motorsport and general engineering sectors.

“To ensure we are competitive and are able to meet customers’ stringent delivery deadlines, we invest in multi-tasking machines with integrated automation.”

This strategy has seen Mechlam invest in a high-performance turning centre with Y-axis and driven tooling capabilities and, more recently, in the new MILL E 700U.

The MILL E 700U 5-axis machine is equipped with a powerful and thermally-stable 36kw/20,000rpm motor spindle, a 120-position ATC and a 7-station Automatic Pallet Changer. It also boasts 30m/min rapids, a directly-driven rotary/tilting table which, through its robust design and responsive dynamics, ensures high workpiece quality (accuracy/repeatability and surface finish) and optimised process reliability.

Says Martin Atherton:

“The MILL E 700U gives us simultaneous 5-axis machining capabilities which enables us to machine complex and intricate features and details on mould tool parts and precision components that cannot be achieved, quickly or easily, using 3 + 2 operations.

“Furthermore, because we can machine parts to completion in a single set up on the MILL E 700U…processing times are reduced (i.e., set up and part cycle times), production bottlenecks are avoided, accuracy is maintained because parts do not need to be transferred between machines…customer lead times are more easily met.”

The productivity and efficiency gains delivered by the MILL E 700U have been amplified with the integration of the workpiece pallet changer.

Says Martin Atherton:

“Using innovative, multi-sided fixturing, we load up the machine’s (seven) pallets at the end of each day to get up to 12 hours additional lights-out, unattended operation. The ability to run attended helps reduce the cost per part and dramatically improves the return on investment.”

About Mechlam Precision Tooling

Mechlam Precision Tooling was established 21 years ago.

In the early days the company was primarily involved in electrode design but, after a couple of years of trading, augmented its offering to also include machining and to provide ‘a one-stop’ solutions service to its customers.

Over the last 18 years, which has seen the company relocate its operations three times to larger premises, Mechlam has grown significantly and now employs 19 people.

Business focus

There are three interconnected strands to Mechlam’s business activities:

• The machining of high-precision parts for plastic and rubber injection mould tools (i.e., mould inserts, bolster plates, slide bodies, pins etc.), for mould making customers operating in the medical, pharmaceutical, ophthalmic, personal care and hygiene, and automotive sectors etc.

• The design and manufacture of innovative, high-quality fixturing (i.e., specialist work-holding machining and inspection solutions) supplied by Mechlam to a number of manufacturing companies as part of turnkey and process improvement solutions they supply to their customers.

• The machining of high-quality components (prototypes and one-offs, through to small-to-medium batch series) to a growing number of customers requiring access to a proven precision subcontract machining specialist.

Differentiation

Mechlam Precision Tooling is committed to continuous improvement and regularly invests in its people, in its plant and equipment, and in its processes and systems.

The company’s ethos, and how it achieves differentiation in the market, is through its focus on:

a) Quality: (reflected in its ISO 9001: 2015 accreditation)

b) Technology: (regular and prudent investment in the latest and most advanced manufacturing technologies, as evidenced in the acquisition of the new VCE 1200 Pro and MILL E 700U machines)

c) Customer satisfaction: (high customer retention levels and organic growth are evidence that the company is well respected and regarded by its customers).

Covid-19

The diversified nature of Mechlam’s business operations and the company’s ethos and culture were under pressure with the outbreak of the pandemic when, virtually overnight, 50% of its business (i.e., existing and planned work) disappeared.

Explains Martin Atherton:

“The global automotive and medical sectors were paralysed, and the ramifications were felt throughout the supply chain.

“Cancelled and postponed orders from a number of our mould making customers, in particular, did hit turnover but, fortunately, an increase in demand for our specialist fixturing design and for our precision component subcontract machining services helped pull us through in what was a difficult time.”

Having high-productivity and high-performance milling, turning and EDM machines at its disposal was critically important in helping Mechlam weather the storm.

It has proved equally important in helping the company capitalise on opportunities in the post Covid era.

Concludes Martin Atherton:

“We invested in the two new Mikron machining centres during the pandemic because we needed to improve our machining (milling) capacity and capabilities.

“The investment would enable us to grow the precision subcontract machining side of the business, which was extremely buoyant, without compromising our ability to respond to our mould tool customers.”

“Now we are getting back to normal, and business from our mould making customers has returned, the decision to invest in new machines has been vindicated: we are stronger, more capable and more productive than ever.”

The future

As part of its continuous improvement programme, Mechlam constantly monitors and benchmarks its performance – identifying and addressing weaknesses when and where they are found.

Later this year (2022), the company will upgrade its wire EDM capabilities by investing in a new high-precision AgieCharmilles CUT P 350 Pro machine and will increase and modernise its inspection department.