Dean Langford has been appointed Managing Director, MetLase
Published: 27.11.2024
With over 20 years’ senior engineering, manufacturing and supply chain management experience for businesses including McLaren Racing, Cullum Detuners, Ishida Europe and most recently Safetykleen, where he was Managing Director, Group Manufacturing, Dean has a strong track-record of developing high performing, multi-disciplined teams throughout the manufacturing supply chain, and leading businesses through periods of significant strategic and operational growth in the UK and EMEA.
He will lead the strategic development and growth of MetLase’s engineering solutions for safety and mission critical industries, and accelerate go-to-market opportunities for a growing portfolio of manufacturing optimisation, robotics and automation solutions.
Unipart Technologies Group, Managing Director, Dr David McGorman said:
“I am really pleased to add Dean to the Unipart leadership team and to have his experience leading our MetLase business into the future.
“His technical background, coupled with experience in applying continuous improvement, quality and safety best practices across manufacturing and engineering operations will support the ongoing development of MetLase’s unique smart manufacturing and optimised tooling and assembly solutions for customers in Unipart’s target markets, including; automotive, healthcare, aerospace & defence, technology and rail.”
Dean Langford, Managing Director, MetLase said:
“I am delighted to be joining MetLase, a Unipart Company with a fantastic reputation in British manufacturing, and a portfolio of solutions to optimise productivity, efficiency and sustainability across the end to end engineering and manufacturing supply chain.
“At the heart of this are teams of great people and a unique culture of engagement and continuous improvement. I am really looking forward to working with our engineers and technology specialists, to
further understand the needs of our customers and target markets, and ensure we are setup with a strategy to exceed these customer needs and deliver scalable solutions that drive the business forwards.”
MetLase launches two ‘digital benches’ at Smart Factory Expo
Published: 07.06.2023
Helping manufacturers improve productivity, reduce assembly time, and harvest critical data.
Metlase will showcase its Component Assembly Bench and Repair Bench at this year’s Smart Factory Expo, taking place in Birmingham (June 7-8) as part of Manufacturing and Engineering Week.
We will have both products on display at Stand L108, with a host of technical experts on hand to talk visitors through the importance of switching to smart tooling to speed up time to market and streamline production cells.
The Repair Bench includes a digital hand tool that optimises and digitises physical data gathering to boost productivity by 40%, whilst also eliminating errors and providing a full digital quality audit trail.
“Demand for automation, precision, and efficiency in manufacturing processes is growing across a vast array of industries and that’s really fuelling our growth,” explained Mat Marsh, Managing Director of MetLase.
“Our proposition leverages the benefits of a digital technology platform with our specialist manufacturing expertise and experience, giving many existing and potential customers access to ‘smart digital’ features that deliver immediate tangible benefits.”
He continued: “Smart Factory Expo will be the first time we will bring our Component Assembly Bench and Repair Bench to a major industrial event. These automated solutions have previously not been possible and our focus on real-time inspection of manual processes can provide unprecedented levels of productivity.
“We will also be showcasing how our fixturing/tooling can be further enhanced by incorporating MetElements into the overall solution. “This proven MetLase digital platform has been created so that it can integrate almost any type of sensor or digital device into bespoke fixtures and products, accelerating speed to market and securing a level of performance not achieved by other alternative joining techniques.”
The Repair Bench for testing electrical components has been developed in partnership with industry and aims to enhance electrical testing, increasing productivity and delivering higher-quality components.
MetLase engineers have been working on the innovation for over a year and expect it to boost reliability, reduce downtime and, importantly, improve safety for users in the UK. This product will be joined on the stand at Smart Factory Expo by the Component Assembly Bench. It incorporates advanced features, including precision measurement tools, integrated sensors and data management, the latter providing real-time data insights that optimise workflow and can help reduce waste.
Mr Marsh concluded: “A lot of companies are offering digital manufacturing, but few can bring solutions to market that have been distilled from significant experience of working with OEMs and Tier One companies. Incorporating MetElements into fixturing/tooling means clients can enjoy the best of both worlds – industry-leading engineering in a customisable digital platform that gives you greater control, greater insight and greater performance.”
We’re delighted to be exhibiting at Engineering Solutions Live 2023, which is now open for registrations!
Returning to the British Motor Museum in Gaydon on Thursday 23rd March 2023, Engineering Solutions Live is your one-stop-shop for new contacts and thought leadership in the engineering sector. Configured for busy design and production engineers, the event provides the opportunity to visit market-leading suppliers and solution providers, network with senior decision-makers from across the UK and boost your learning during our expert-led conference session.
Visit their website to find out more and to register for your FREE ticket! We look forward to seeing you there!
Stewart Lowth leads digital transformation based on the practical approach honed from MetLase’s expertise in tooling and fixturing.
Published: 16.02.2023
For Product Development and Innovation Manager Stewart Lowth and the team, getting the right data to the right people is crucial to making informed decisions. He said:
“Optimising productivity of your manufacturing resources is critical. That’s why we recommend our customers to look to the shop floor first to understand the tangible and quantifiable benefits of Industry 4.0 and digitisation.
“Taking advantage of systems that collect and distribute manufacturing data can help you gain greater insight into how to optimise your processes. In addition to protecting your significant investment in digital equipment, this approach supports cross-functional teamwork and standardises operations.
“In a recent collaboration between MetLase, Unipart Rail and Manufacturing, we took a manual process for reconditioning relays, digitised and optimised it, and it is now being used in both Crewe and Coventry to refurbish relays with the latest SmartBench iteration making it a repeatable process.”
Stewart leads a working group that meets weekly to discuss wider possibilities of digital transformation. They explore ideas using new digital technologies and cutting-edge mechanical design to drive innovations within Unipart Technologies Group, looking at a range of areas including robotics, medical devices, and smart digital manufacturing products.
“The benefits of smart manufacturing are no longer exclusive to large companies; they are now much more accessible,” said Stewart. “It is imperative that manufacturers of all sizes prioritise digital transformation as a means of staying competitive now and in the future.”
Digital transformation is taking a firmer grip on modern-day manufacturing, with more companies exploring how these technologies can help them achieve cost and operational improvements.
Leading the charge is MetLase in Rotherham, an engineering business using ‘advanced sensor technology’ to deliver innovations that contribute to ‘greener’ travel.
If we could go back 20 years and ask an engineer about the importance of sensors, we may – if lucky – get a shrug of the shoulders.
Transport ourselves forward two decades and the power of collecting data effectively is transforming the way we make everything, whether that is electric cars and the latest smartphones, or body implants and components for use in aerospace engines.
The shift in adoption has been accelerated considerably and an increasing number of companies are exploring how digitalisation can transform their operations, yet there is still uncertainty around the correct choice of technology, the cost and, importantly for all manufacturers, the return on investment.
This is where firms need to take a step back and take a strategic view, turning to experts who have already developed solutions that could be integrated into or modified to suit their operations.
MetLase has been doing this since its inception in 2015 and now boasts a client base of tier 1s, primes and Original Equipment Manufacturers (OEMs) from the automotive, aerospace, Formula One, maritime and power generation worlds.
The Yorkshire-based company, which employs 30 highly skilled engineers at its state-of-the-art base at the Advanced Manufacturing Park Technology Centre, is transforming business operations to be more efficient, cost-effective and responsive through the integration of a variety of sensors.
This isn’t as easy as you think due to the multitude of options, but making the right selection when it comes to sensors and technology is vital when introducing digital technologies.
“Many digitised concepts are readily available to implement into current applications, although selecting the most appropriate and having the right expertise to optimise performance is often overlooked,” explained Richard Gould, Business Development Manager at MetLase.
“Our team of engineers have a deep understanding of digital technologies and have developed a suite of standardised smart products to answer manufacturers’ greatest challenges.
The team works in partnership with our customers to ensure they adopt these products in the smoothest way possible, bringing about rapid improvements in quality, cost and delivery.”
He continued: “One area in particular where we have seen dramatic results is in the application of sensor technology in tooling and fixturing, integrating into MetLase’s smart products, bringing benefits to the entire value chain.”
At the heart of MetLase’s digital roadmap is MetElements, which has been developed so that it can integrate almost any type of sensor or digital device into bespoke fixtures and products.
The 7000 grade aluminium used in these types of components is renowned for its internal residual stresses and its habit of warping during machining; especially if the component is thin walled, as this lowers the geometric stiffness of the final component.
Richard went on to add: “We have a strong working relationship with the AMRC, so used this collaborative partnership to work with its engineers to explore how sensors could be used in adjusting the machining process in real time, compensating for any warping as the part is being cut, and delivering better geometric accuracy in the final component.
“The solution we selected was the implementation of a series of specialised distance sensor units designed to attach to the existing 3rd-party fixturing within the machine tool. The eight sensor modules used low-cost ‘smartphone grade’ sensors and were designed so that they did not interfere with the cutter path.
“Leveraging the power of MetElements, the sensors were also designed to withstand the flood cutting coolant as well as the swarf generated by the milling operation.
“The system gave live feedback about the component’s geometric condition during the milling process, so a 3D display could be created that showed how the component was distorting in near real-time (60Hz).”
Backed by MetLase expertise, the overall programme saw a 12% reduction in the final part weight due to the reduction in wall thickness.
Equally importantly, a negligible distortion was noted due to the pre-planning of the residual stress distribution before machining and this was verified during the process using the ‘smart machining’ sensors.
Daniel Smith, Technical Fellow in the Aerostructure and Landing Gear Team at the AMRC, added his support:
“The project successfully demonstrated the power of adding sensing equipment to existing industrial processes, and the positive impact of harvesting live in-process data can have, in order to validate model data and ultimately improve the quality of the output component geometry.
“MetLase has been instrumental in the implementation of sensor technology throughout this project, working with us from the start and then supporting us with their own design, engineering and digital manufacturing expertise. It has delivered a number of tangible results, but importantly has given us a solid use case on how industry could retrofit low-cost smart i4.0 sensing to existing off-the-shelf-machining equipment.”
Stewart Lowth, Product Development and Innovation Manager at MetLase, concluded:
“MetElements gives us an adaptable platform for any connected technologies to communicate with each other, whether they are traditional industrial automation sensors or modern small-factor smartphone style sensors.
“Just like on the AMRC project, this digital flexibility allows the right sensing solution to be used for the right job; saving money for SME and large organisations alike.”
Stewart Lowth applying advanced sensor technology to deliver innovative fixtures
MetLase supports Rachel Reeves MP visit to the ASCI
Published: 14.10.2022
October 2022 – Rachel Reeves MP, Shadow Chancellor of the Exchequer, visited Unipart House this week to learn about how The Unipart Way can make organisations more productive, more competitive, and more sustainable.
In the new Advanced Supply Chain Institute in Unipart House, Oxford, Group Chairman and Chief Executive John Neill explained to the Shadow Chancellor how The Unipart Way can help solve the productivity puzzle to unlock the growth potential of the UK.
Rachel Reeves met teams at Hyperbat, Unipart’s EV battery manufacturing joint venture, and MetLase, Unipart’s smart tooling company.
The Hyperbat team explained how Unipart Manufacturing has been working for a decade to address the skills gap in UK engineering and manufacturing, and the transition from internal combustion engines (ICE) to zero-emissions mobility.
The Shadow Chancellor saw how the Institute for Advanced Manufacturing & Engineering (AME), Unipart’s unique collaboration with Coventry University, is giving real-world industry experience to the engineers of tomorrow, while helping to reskill engineers with years of ICE experience in EV battery manufacturing.
In particular, Rachel Reeves MP learned about Unipart’s capability in world-class laser welding and how crucial it is in the production of EV batteries.
The MetLase team explained to the Shadow Chancellor how its laser cut reinforcement technology can replace rebar in concrete to improve productivity, sustainability, quality, and safety in the construction industry. They also demonstrated how their SmartBench can make the UK’s manufacturing industry more productive and get unskilled employees on the ladder to learn and become skilled.
Alongside Oxford East MP Anneliese Dodds, Shadow Secretary of State for Women and Equalities, Rachel Reeves saw first hand Unipart’s expertise as a leading supply chain expert at the forefront of the Fourth Industrial Revolution, with a strong focus on sustainability, and employee engagement and wellbeing.
Rachel Reeves MP, Shadow Chancellor of the Exchequer, said: “It was helpful to understand how Unipart is working to solve the productivity puzzle, one of the big challenges facing the country.
“The UK has huge opportunities in being a global leader in some of the industries of the future. Particularly as some of those industries are going to help us get to net zero, like batteries for electric vehicles.
“So it’s really exciting to see that Unipart is already leading the way in some of that manufacturing and design. In the years to come, I want Britain to be exporting cars all around the world, but we’re going to need innovations like those happening here at Unipart to realise that potential.”
John Neill, Unipart Group Chairman and Chief Executive, said: “For Britain to achieve its growth objectives it must put productivity improvement at the top of its agenda. Improving productivity is at the heart of the nation’s quality-of-life and I was delighted to be able to show the Shadow Chancellor how our hundred-million-pound investment over 30 years in The Unipart Way helps to drive productivity for our company and our clients.
“In the last five years we have further developed The Unipart Way tools and techniques to enable us to manage our business through a digital lens compared with the analogue lens of the past and it is fundamental to our drive for carbon neutrality by 2030 and net zero ahead of 2050.
“The Unipart Way body of knowledge is critical to helping our fellow employees learn the new skills as we transition from 1st tier suppliers of internal combustion components to the New World of battery electric vehicles. We were pleased to show the Shadow Chancellor our Hyperbat factory which after several years of developing, refining and perfecting the complex technologies needed is currently manufacturing batteries which need to meet exceptional performance requirements.”
L-R: James Simester (Unipart Technologies Group), Anneleise Dodds MP, John Neill, Rachel Reeves MP, Richard Gould (MetLase)
MetLase supports sculpture artist to construct inspirational sporting commission for Commonwealth Games
Published: 22.04.22
MetLase, a collaboration between Unipart and Rolls-Royce, is among the UK’s most cutting-edge technology manufacturers supporting sculptor Jacob Chandler with his commission for the Birmingham 2022 Commonwealth Games.
The 250cm sculpture of a para-athlete will be installed in Birmingham New Street station between 16 June and 5 September, in celebration of the Birmingham 2022 Festival, the cultural programme for the international sporting event.
MetLase is providing precision laser cutting of material for the sculpture. Through years of continuous improvement, MetLase has mastered laser cutting to such an extent it allows the maximum known precision from the technology. Many different metals can be laser cut, and the parameters of the laser cutter are carefully adjusted according to the design.
“We love the industrial automotive style of his pieces. It reflects our parent company’s markets and our own involvement in high-tech, mechanical engineering. We are proud to be associated with a piece that has such an important message”
Richard Gould, MetLase Sales and Business Development Manager
Further information will be shared periodically as it becomes public information regarding the manufacture.
For further information on our core technologies, click HERE.
MetLase is providing precision laser cutting of material for sculpture artist Jacob Chandler
MetLase SmartBench demonstrates the art of the possible at the UKRRIN Technology and Innovation Hub
Published: 26.01.22
The MetLase SmartBench will play a key role in the development of new technologies and solutions for the rail industry.
Located at the newly launched UK Rail Research and Innovation Network (UKRRIN), the showcase for the £92m UKRRIN project, the technology is available for demonstration to assist in solving strategic industry challenges and develop the next generation of products and services.
The SmartBench focuses on challenges faced in manual assembly of mechanical, electrical and electronic products, delivering a ‘no-fault-forward’ approach designed to eliminate production defects by delivering 100% quality. The digitally-enabled assembly workstation enables companies to implement Industry 4.0 technologies in an agile way, covering almost all manufacturing processes.
Designed and manufactured by MetLase engineers, this adaptive workstation provides operators with on-screen instructions and physical aids to complete the required process. The design is a response to rapidly changing product variability, providing speed, customisation and usable data to our customers. Using this technology provides manufacturers consistent products with data collected, which has seen quantitative business benefits such as a 45% process time reduction and reducing defects by 35%. The bench can be available both pre-installation and adjusted to fit existing workstations.
The SmartBench provides a no-fault-forward approach to your manufacturing process by featuring;
Data being recorded throughout the assembly process
Maintains traceability at all stages
Video based instructions to the operators
Continuity of connected digital verification at all stages
Data collected at this magnitude presents significant business benefits and can ultimately be used to improve product design.
SmartBench will feature alongside other interactive displays in the UKRRIN Centre of Excellence which launched at an event covering the theme of ‘Where Great Ideas Converge’ with a number of UK rail leaders providing insights into innovation and digital transformation. This new hub will support the sector in translating academic research and innovation to solve strategic industry challenges and to enable and develop the next generation of products and services supporting decarbonisation, asset management and digital.
Richard Gould, Sales Manager at MetLase Ltd, said “The SmartBench is a great addition to our suite of digital products that we developed in response to our customers’ needs. The significant levels of data collected helps our customers to know more than ever before about their manual processes, which in turn enables data driven process improvements, previously unattainable. The SmartBench delivers the greatest levels of process efficiency achievable and provides a no-fault-forward production environment. Using our SmartBench creates reliability, quality and consistency for our customers.”
MetLase SmartGauge technology seamlessly integrates into the NCC’s Made Smarter Innovation Hub
Published: 13.12.21
The manufacturing sector has plenty of digital opportunities, but innovation isn’t easy without upfront investment and the right environment. But what if I told you there is an opportunity to test quick-fire projects and early-stage technologies in a secure, industry-like environment with expert support and skills?
Adopting digital tools and doing things differently, particularly when thinking about improving efficiencies and resiliency, has been amplified by the COVID-19 pandemic. MetLase have been selected to showcase their Digital SmartGauge at the National Composites Centre (NCC) Smart Factory Innovation Hub. A great opportunity to offer virtual and physical digital testbed environments, providing manufacturers the chance to explore new value propositions of digital transformation.
We understand manufacturers often operate in highly complex environments with safety being the number one priority. As a manufacturer, you are now able to visit the Innovation Hub to test our technology that may be the solution to your challenges. This testbed environment gives you the opportunity to think differently about what outcome you require and to look into updating your current processes and systems to adopt new complex digital systems.
Making innovation a reality
MetLase is able to offer manufacturers practical advice about how to gain adoption for innovation projects internally. This advice is focused on specific solution areas, as well as more broadly on company processes.
Using a collaborative approach, our design engineers work directly with manufacturers to understand your processes. Using the MetLase core digital technology platform, a concept is quickly developed to meet those requirements and drive your productivity improvements. The flexible and fast manufacturing processes MetLase offer enable early demonstrations on the table, often at full-scale.
Adoption is key
Whilst understanding digital investment in new technology is important, so is ensuring that you have a plan to bring customers and the business along with you. Our engineers are fully committed to coaching your business to drive digital transformation adoption to ensure your projects are a success.
Jonathan Butt, Deputy Chief Engineer at the National Composites Centre added ‘Working with MetLase has allowed us to accelerate, integrate and showcase innovation of digital technologies to our partners and member companies. Not only has MetLase managed to deliver a solid engineering solution but the SmartGauge is combined with the latest digital technologies to assist us in our mission for adoption of economic impact within a business environment”.
MetLase SmartGauge in the NCC Smart Factory Innovation Hub
What can seem like a daunting problem in your business can sometimes be simply resolved by transferring technology from another sector – but accessing and transferring can be difficult. MetLase is experienced in this horizontal innovation transfer.
In one of the most disruptive years in manufacturing, some businesses have embraced and accelerated their digital journeys while others were required to put digital transformation on hold and are now playing catch-up. In both of these cases, businesses can benefit from MatLase’s approach.
MetLase, a joint venture between Unipartand Rolls-Royce, explains how horizontal innovation could be the key to unlocking potential growth opportunities to bring emerging businesses out of the COVID-19 pandemic stronger and more agile to create competitive advantage to the manufacturing industry.
With foundations based on horizontal innovation, MetLase draws on the heritage of both parent companies in aerospace and automotive. The vision, to take expertise in fast-make tooling and fixturing methodologies cross-sector to rapidly solve some of industries greatest challenges.
Breaking down your current restrictions
The UK is recognised for its creativity, research, and innovation, but often technologies or processes can get locked into one sector or industry. MetLase offers digital manufacturing solutions which can be embedded in your manufacturing processes to standardise for consistent and accelerated quality and delivery.
By sharing best practice cross-sector, MetLase wants to break down barriers to enable innovations to be used where they are needed, and not just in the sector in which they are created.
The key to success
“The power of a true cross-sector solutions provider like MetLase is the visibility of the engineering challenges and how we have solved them across the sectors we serve. Combined with a highly skilled and knowledgeable team, this mix accelerates horizontal innovation, allowing us to solve the complex manufacturing challenges that our clients pose” explains Dr Stewart Lowth, Product Development and Innovation Manager at MetLase
Stewart continued, “This horizontal innovation is especially evident in our digital platform, where inspiration from highly connected and robust consumer electronics has been applied to industrial measurement. In one example, “smart-phone” style sensors were used to replace a manual measurement process. We looked beyond traditional industrial sensing and found a synergistic technology that matched the accuracy and cost requirements of our client, predicting a time saving of up to 45%.
MetLase has continued to adopt, diversify, and develop Industry 4.0 technologies to drastically improve the performance of their fast-make tooling and fixturing.
Founded on a premise of horizontal Innovation, MetLase parent companies joined forces with a mission to adapt our advanced aerospace-grade fixturing technologies to the production challenges of other industries. Beneficially, this mandate also allowed MetLase to level the learning from these other industries back into the aerospace sector, addressing the challenges they faced around lowering costs and increasing productivity.
Lowth concluded: “We believe we have an engineering team experience, as well as expertise across multiple sectors – knowledge and capability needed to deliver a solution for every problem imaginable.
“So, we invite industry to challenge us with your manufacturing problems and let us deliver the solution.”
