Introduction: What we mean by automation in engineering and how we invest

In engineering, automation is the use of technology and robotics to replicate some of the manual operations completed by machinists. It has transformed the way we operate and manufacture high-quality components. At our company, we have embraced automation to streamline our operations and enhance efficiency.

Embracing automation has proven to be a game-changer for us. Since 2019, under new leadership, we have made substantial investments in cutting-edge machinery. However, our approach is careful, and decisions are thoroughly analysed before each purchase.

Prior to acquiring any machinery, we conduct a strategic analysis, evaluating the options and benefits of each machine to make the best investment choices. It became evident that to maximize our output, we had to specify the machine to be as automated as possible. During discussions with machine tool dealers, we would show them the jobs we wanted to machine, and then seek guidance on how to maximise the lights-out running.

Automation initiatives and technologies Ashtead Engineering Company has adopted

One of the most prominent applications of automation in our facility is the integration of a robot loader. These highly versatile machines tirelessly load raw materials into CNC machines and seamlessly remove finished parts, eliminating the need for constant human intervention. This not only reduces the physical strain on our machinists but also ensures consistent and efficient material handling.

We have also implemented automated bar feeds. These systems tirelessly supply raw material to the CNC machines, ensuring an uninterrupted flow of work and minimising downtime. This automation eliminates the need for manual bar insertion and removal, freeing up our machinists to focus on critical tasks like quality control and programming.

In addition to these physical automation measures, we also employ feedback systems using probing technology. These systems continuously verify that the machine is accurately machining the parts to the specified dimensions. If any deviation is detected, the machine’s offsets are automatically adjusted, ensuring that every component meets the stringent standards of our customers. This feedback mechanism not only maintains precision but also minimises the risk of rework and rejects.

Our commitment to automation extends beyond these specific applications. We are constantly exploring new and innovative ways to integrate automation into our processes, striving to further enhance efficiency, productivity, and quality control. As we advance our automation capabilities, we remain committed to providing our customers with the highest-quality precision engineering components.

How automation has transformed Ashtead Engineering Company

Automation has been instrumental in enhancing our efficiency, productivity, quality standards, and ultimately, our overall business performance.

Increased production and capacity

At Ashtead, we operate a single shift, we have no inclination towards running night shifts. We are utlising automation to run our shift for us! This has significantly increased our production and efficiency, while maintaining overhead costs. However, leaving machines to run un-manned poses challenges in maintaining high-quality standards. We have tackled this problem by utilising in-cycle probing and increasing the frequency of our roaming inspection.

To achieve our long-term business goals and increase our turnover, we have opted for automation instead of adding extra shifts or expanding the size of our factory. Automation has enabled us to almost double our production hours, thereby increasing our capacity and catering to more customers than we could have done previously.

Furthermore, automation has enabled us to expand our product portfolio, venturing into new and more complex machining projects that would have been challenging to undertake with our previous manual operations. This diversification of our offerings has further enhanced our market competitiveness and strengthened our position within the precision engineering industry.

Employee Benefits

As a business, we have seen the positive impact of automation not only on our operational efficiency but also on our employees. By automating repetitive and labor-intensive tasks, our machinists now have the bandwidth to concentrate on strategic initiatives such as quality control, programming, and continuous improvement. It has also empowered them to engage in multi-manning across multiple machines. Our investments have resulted in more competitive pay rates and less man-hours spent, including over-time, making it a win-win situation for both the business and our employees.

Way forward

Ashtead Engineering Company is committed to embracing automation as a strategic imperative that drives our success. Our objective is to make every new machine we purchase as automated as possible. We will continue to invest in cutting-edge machinery, pursue innovation, and develop a skilled workforce to maximise efficiency, productivity, and quality while maintaining a fulfilling work environment. We also believe that this approach will also enable us to provide exceptional value to our customers.

Explore how AEC’s commitment to precision engineering ensures unparalleled quality control in every project. Discover our approach to custom engineering solutions.

In precision engineering even a micron-level deviation can mean the difference between success and failure. At Ashtead Engineering Company (AEC), we’re not just aware of this fact – we live by it. In this post, we dive into how our commitment to quality sets us apart and ensures success in every project, from CNC machining to custom engineered solutions.

Our Commitment to Excellence

At AEC, quality isn’t just a goal; it is an integral part of our ethos. Our journey in precision engineering is marked by a relentless pursuit of excellence. Our focus on quality has been pivotal in our growth and success over the years. We understand the high standards demanded by our clients, especially in sectors like Aerospace and Defence, where precision is paramount.

Where Technology Meets Skill

Our skilled machinists work seamlessly with advanced technology to deliver high-quality components that meet strict tolerances and exacting requirements for accuracy and repeatability. Our commitment to high-quality, cost-effective machining services has made us the leading provider of precision machining and design services in the Southeast & London region.

Growth Through Quality Engineering

Our growth strategy is simple yet effective – retaining both existing and new customers through exceptional quality products and services. Our proven quality records have helped us achieve significant growth in the past years, and we are confident of continuing this trend in the future.

We understand that our target market demands extremely high and demanding standards, and we are always up for the challenge. As a subcontract manufacturer, we know that our clients’ expectations are sky-high, and we exceed them by employing the latest technology and equipment and skilled and experienced engineers to ensure precision and accuracy in every project we undertake.

We are continuously investing in research and development to stay ahead of the competition and provide innovative solutions to our clients. Our dedication to excellence and quality has helped us establish a reputation as a reliable and trustworthy partner for precision engineering.

How AEC Ensures Quality

At AEC quality control is not just a priority, it is a foundational principle guiding everything we do. Our approach is multi-faceted, focusing on continuous investment in cutting-edge machinery and rigorous inspection protocols to maintain the high standards we set for ourselves.

Investing in machines not only improves reliability and repeatability, but also allows us to incorporate in-process measurements. We recognise that investment in inspection equipment is often overlooked by machining firms, but we are dedicated to invest in this critical area. For instance, we have recently acquired the TVM35, showcasing our commitment to utilising modern equipment.

However, our pursuit of quality extends beyond our equipment. We firmly believe in the power of collaboration with our clients. By actively seeking and incorporating their feedback we are able to better align our processes with their exact needs. Regular audits are conducted with our clients which provides us with invaluable insights, covering everything from paperwork to machining. This collaborative approach ensures we stay aligned with the evolving demands of the industries we work across and fosters and environment of continuous improvement.

Partner with AEC: Where Precision meets Passion, and Commitment meets Creativity

At Ashtead Engineering we offer a full range of CNC and conventional machining services. But what exactly is CNC machining and why is it so popular in the manufacturing and engineering industries?

The introduction of Computerised Numerical Control (CNC) machining in 1952 marked the beginning of a transformative era in precision engineering. This groundbreaking technological development shifted the manufacturing industry from traditional manual methods to automated processes, enabling enhanced precision, streamlined processes, and higher component quality.

Advancing precision: AEC’s evolution in CNC machining

AEC adopted CNC machining in 1982, evolving from humble beginnings with peg-board and cam-auto machines to embracing the then cutting-edge technology of Hebert Husky and Mazak machines. This new technology marked a pivotal turning point, allowing us to offer a significantly more advanced and comprehensive suite of CNC machining services , catering to the diverse needs of our clients.

Over the years, our journey with CNC machining continued to evolve. AEC expanded its CNC capabilities, delving deeper into CNC turning and milling and continuously exploring and integrating the latest technological advancements. Our commitment to excellence led us to consistently invest in the latest modern equipment, reflecting our dedication to maintaining the highest precision manufacturing standards.

Currently, AEC is at the forefront of integrating robotics and automation into our processes, reflecting our ongoing commitment to efficiency, accuracy, and meeting the dynamic needs of our clients. As we look towards the future, AEC remains poised to embrace emerging technologies, ensuring that our clients benefit from the latest innovations in precision engineering.

Basics of CNC

The manufacturing industry was forever transformed by CNC machining which enabled the automation of a process that previously required engineers to manually wind handles to move the machine axis. The modern day process involves using computer programs to control the movement of machine tools, which has made the process more efficient and accurate.

CNC machines are used widely in turning and milling, but you can also use them in grinding, assembly, and other forms of machinery. A computer can move multiple axes simultaneously, creating more complex shapes, making it possible to manufacture parts and components that were not previously possible without specially-made form tools. The manufacturing process starts with a digital design of the part or component.  This design is then converted into a set of instructions that the CNC machine can understand. These instructions are then sent to the machine, which uses them to control the movement of the machine tools.

What is CNC milling?

CNC milling is a subtractive manufacturing process that involves the use of computer-controlled machines to remove material from a workpiece. The process starts with a digital design of the part or component that needs to be manufactured. This design is then converted into a set of instructions that the CNC machine can understand.

The CNC machine uses these instructions to move the cutting tool along the X, Y, and Z axes to remove material from the workpiece. The cutting tool can be a drill, end mill, or any other tool that can remove material from the workpiece. The CNC machine can also rotate the workpiece to create complex shapes and contours.

Advantages of CNC machining

CNC machining has become the norm in the manufacturing industry and has revolutionised many industries by providing numerous advantages over traditional methods.

This mechanism can create shapes and geometries that were previously impossible with traditional machining methods. You can use standard tools to create complex shapes, eliminating the need for specially made form tools, saving time and reducing production costs.

CNC machining also reduces the number of operations required to produce a part. With modern CNC machines, you can perform multiple operations in a single setup, reducing the time and cost of production. Some of the critical benefits include precision, repeatability and scalability:

Precision

You can achieve high accuracy and consistency, which is impossible with manual machining. This precision is essential in aerospace, medical, and automotive industries, where even the slightest error can have severe consequences.

Repeatability

Once you have programmed a CNC machine, you can produce identical parts repeatedly without any variation. This consistency is crucial in mass production, where you need to produce a large number of parts with the same specifications.

Scalability

It allows manufacturers to produce parts quicker, which makes mass production viable, economical and efficient.

Components and working

The structure of a CNC machine is similar to that of a manual machine, comprising a spindle, work holding, axis, tool holding, and more. However, the key difference is that a motor powers the movement of the axis, and there is feedback in the form of an encoder or linear scale gauge, allowing the computer to control it.

The spindle is responsible for rotating the cutting tool or chuck, while the work-holding component secures the machined material in place. The axis component controls the movement of the cutting tool in different directions. On the other hand, the tool-holding component secures the cutting tool in place and allows for easy replacement.

CNC machines have a control panel that allows the operator to input commands and adjust settings. This panel may include a screen for displaying information about the machining process, as well as buttons for making adjustments.

Overall, the major components of a CNC machine work together to automate the machining process and produce high-quality parts with minimal human intervention.

Conclusion

CNC machining is the backbone of modern manufacturing. It is an indispensable tool used in everything, from the production of smartphones to machining for various industries. The technology has seen significant advancements, resulting in streamlined processes and improved efficiencies.

The aerospace, automotive, medical, and electronics industries rely heavily on CNC machining. It has made it possible to produce complex designs and shapes that were not possible with traditional manufacturing methods. It benefits large industries such as oil and gas and aerospace but also makes products more accessible to consumers (which we often take for granted).

By taking advantage of modern CNC machining manufacturing processes are significantly more economical, reducing waste and increasing productivity. It has enabled manufacturers to produce high-quality products at a lower cost, making them more competitive in the market.

With its unmatched precision and accuracy, CNC machining has redefined modern manufacturing, transforming production processes, making them not only more efficient but also more cost-effective. The importance of CNC cannot be overstated, and it will continue to be a driving force in the future of manufacturing.

Explore the power and precision of CNC machining with our state-of-the-art equipment

Here are some of the ways that solar panels have benefited our business:

Lower Energy Costs

The most obvious benefit of solar panels is that they generate electricity from the sun, which means that we have to buy less electricity from the grid. This has translated into significant savings on our energy bills, which is particularly important given the volatile energy markets we have seen in recent years. While the initial investment in solar panels can be significant, the long-term savings are substantial, and we expect to recoup our investment within a few years.

Improved Energy Efficiency

Another benefit of solar panels is that they encourage us to think more carefully about how we use energy in our factory. By monitoring our energy usage and the output of our solar panels, we have been able to identify areas where we can improve efficiency, such as replacing outdated equipment with more energy-efficient models or adjusting our production schedule to take advantage of peak solar output.

Reduced Carbon Footprint

As business owners, we believe that it is our responsibility to minimize the impact of our operations on the environment. By using solar panels, we are able to generate clean energy and reduce our company’s greenhouse gas emissions. This is not only good for the environment, but it also helps us to position our company as a socially responsible and environmentally conscious business.

Positive Brand Image

Finally, installing solar panels has helped us to differentiate our business from competitors and improve our brand image. In today’s market, many consumers are looking for companies that are committed to sustainability and reducing their environmental impact. By demonstrating our commitment to solar energy, we have been able to attract new customers and strengthen our relationships with existing ones.

In conclusion, installing solar panels on the roof of our factory has been one of the best decisions we have made for our business. By reducing our energy costs, improving energy efficiency, reducing our carbon footprint, and improving our brand image, we have been able to reap numerous benefits while also doing our part to protect the environment. We would encourage other business owners to consider the potential benefits of solar energy and explore whether it could be a good fit for their operations.