MetLase launches the Digital Gauge

MetLase launches the Digital Gauge, significantly speeding up the inspection process, reducing scrap and collecting actionable data

Imagine a production line where a 90 minute quality check would result in 42 fuel systems being scrapped. Now imagine one with a 4 second quality check. That’s the transformation that MetLase has delivered.

In our current climate, waste like this in any business is a cost that needs to be avoided, so when a one of the UK’s largest plastic fuel system manufacturers brought this issue to the MetLase engineers to see what could be done.

The customer currently uses the New Generation Fuel System blow-moulding process to produce plastic fuel systems. Due to the complicated nature of this process, machines are required to run 24/7 as a high level of heat is required before production can start. As with all manufacturing processes, parts are inspected regularly to ensure they adhere to stringent quality standards. With around 49 points of data to inspect, this process can take around 40-90 minutes. To complicate this further, a number of components are enclosed within the tank. If the production line stops due to a fault, a substantial amount of scrap can occur.

Complexity

A fuel tank is one of the most safety critical components of a car. The production process produces roughly 1 plastic fuel system every 38 seconds, quality inspections can take up to 90 minutes per system. If defects are found, production would stop, but worse than this, up to 42 fuel systems have potentially become waste.

By using a range of different technologies used in multiple sectors, our MetLase Engineers offered a solution for our customer’s unique problem. Digital technology was applied to solve the manual inspection process, turning this to a digital solution that automates the inspection, providing an instant assessment of the fuel tanks.

4 Second Check

The result, a Digital Gauge which has over 50 different sensors which can inspect the fuel system instantly, reducing the inspection time from up to 90 minutes to just 4 seconds.

MetLase engineers developed this technology which includes ‘plug and play’ which integrates into the Digital Gauge fixturing system which could not be done with existing technologies.

What Our Customer Says…

“Based on the initial concept, we predict this new solution can be used across all our 34 production facilities globally. Improving the efficiency from 90 minutes to 4 seconds per tank each day has considerable benefits from the waste reduction, manning time and significant cost savings. MetLase has gone above and beyond fixing our manufacturing solution to provide expectational benefits to our main production process, delivering major benefits to the lifetime of this product”

Tried, tested and implemented, the new Digital Gauge fixture is now being developed to drive efficiencies across the partner organisations across a global basis.

What Our Engineers Say…

“The problem our customer came to us with is one many engineering companies face. Manual processes take time and resources out of the business where digital solutions can be implemented. By offering Industry 4.0 solutions, the Digital Gauge plays a part in the transition from manual to the digital transformation of a company. The additional benefit from machine learning accelerates this transformation of the way the business operates offering their customers a competitive product.”

Digital Evolution not Revolution

News / By Jenny

Digital Evolution not Revolution

Richard Gould, Business Development Manager at MetLase, attempts to remove some of the myths around digital manufacturing and why engineers should focus on digestible and actionable data as part of the bigger picture

Manufacturers can be forgiven for feeling a little fatigued when they hear the words ‘digital manufacturing’.

So-called industry experts, consultants and anyone with a remote interest in making money out of new software solutions have done their best to inject so many buzzwords into the sector that engineers are being turned off to the real benefits it offers.

Industry 4.0, digitisation or IoT have become commonplace in the business dictionary, fitting in perfectly next to productivity, cashflow and profits…the only issue is very few people know what they actually translate to on the shopfloor.

“We prefer to look at it in a completely different light and hopefully one engineers will switch on to.” explained Richard Gould, Business Development Manager at MetLase, a specialist in world-class tooling and intelligent fixturing and components.

“For us, digital manufacturing is not a standalone entity. Instead, it should be a critical aspect of the process and operation and it should revolve around data and, specifically, digestible, actionable data.”

He continued: “It’s our responsibility, as technologists, to demonstrate how easily and cost effectively data can be harvested, automatically digested and analysed, and then put to use immediately, in order to get the maximum benefit from it.

“In real time, this could be identifying areas where we can improve processes and procedures, reduce product defects, improve productivity and speed up cycle times significantly.”

MetLase, a joint venture between Unipart and Rolls-Royce, identified early on in its development the importance of creating a suite of digital products that would deliver bottom-line benefits to its clients in the automotive, aerospace, construction and renewables.

This involved taking traditional manufacturing principles focusing on assembly, bonding, measuring, workholding and assembly workstations and exploring how they could digitise them in a way that would allow them to provide their core function whilst also creating intelligent data.

Over the course of the last two years this has seen engineers at the Rotherham-based firm develop five smart products, including the Digital Gauge (conducting a digital dimensional inspection process), Smart Bench (ensures no-fault forward in the assembly process as well as connecting up-front supply chains) and Smart Cell.

The latter covers multiple manufacturing processes and can enable human interaction with cobots and robots, enabling tasks such as stock control and automated direct-to-bench supply of components and aftermarket in-service and maintenance requirements.

Richard went on to add: “We haven’t stopped there, taking a similar approach to Smart Machining, creating a smart fixture dedicated to holding a component whilst also gathering multiple types of process parameter data, such as clamping forces, vibration, temperature, and dimensional measurement – all geared towards giving the client better process control and ongoing improvements.

“The Smart Shield is the last of our digital products and digitally monitors and controls the level of localised gas shielding during the welding of a component. This technology is specifically suited to components produced in exotic alloys, which require welding under an inert atmosphere to ensure weld quality.”

These digital products are already in operation and delivering tangible benefits to clients on high-profile projects stretching the boundaries of innovation.

Examples to date include MetLase engineers working with a leading supercar manufacturer to support in-line composite pre-form measurement and the use of digital gauges at Kautex Unipart Limited (KUL) in Coventry to support the inspection of blow-moulded plastic fuel tanks.

The introduction of the new technology means the process takes just four seconds, replacing an inspection system that would usually take 45 minutes, during which time the line would produce parts. If a fault was found at this stage, all the components made in that period would be destined for the scrap pile.

In addition to the speed increase, it also allows data to be collected that is ‘actionable’ for process improvement and machine learning.

Richard concluded: “This is just the start, as more and more customers are switching on to the benefits of digital manufacturing in the overall process.

“And we’re not just talking about impact on shopfloor. One project we’re currently exploring is the introduction of a Smart Bench to support a maritime application, where a global business has won a contract that includes an element of regenerating a region’s manufacturing sector.

“The bench potentially helps in that it instructs and inspects so well that operators, who are not highly skilled engineers, can now fulfil the operation, giving them employment and a vital start in manufacturing.

“This goes back to the point about making the benefits of digital manufacturing easy to understand…if done correctly it will help companies improve their operations, become more productive and create employment and new opportunities for UK manufacturers.”

Developing my career with MetLase

Employee Spotlight, News / By Jenny

Developing my career with MetLase

Stewart Lowth, Product Development and Innovation Manager, MetLase Limited

After just 3 years with MetLase, Stewart Lowth has recently been promoted to Product Development and Innovation Manager – recognising him as one of the leaders in shaping a business culture required for innovation to succeed within MetLase.

Stewart’s engineering career began 2000, at a design consultancy that specialised in automated automotive fixturing. After 11 years Stewart moved on to undertake a PHD in fixturing sponsored by Rolls-Royce as a way of sharpening his technical skill set. This led Stewart into academia and teaching at the University of Nottingham as Assistant Professor in tooling and fixturing, where he successfully supervised a number of his own Rolls-Royce funded fixturing PhD students to completion. As part of his innovative research, Stewart worked closely with Rolls Royce on complex manufacturing problems and it was here he learned more about MetLase, a new company formed on engineering expertise with a vision to innovate.

In 2017, Stewart officially joined the team where he has been given time and resources to expand his vision and innovate projects.

Stewart said “The whole team is really engaged and wants to contribute to the company’s success. It’s great to work in a team that really values your experience”

“With my background in teaching, this role has provided me with the opportunity to work with the team to embed a culture which will provide confidence for them to offer complete digital solutions and propose innovative problem solving solutions to our customers without feeling out of their depth”

One of Stewart’s most notable and more recent challenges in this role includes the UK’s Ventilator Challenge UK (VCUK). The team were faced with having to quickly develop a working ventilator to a new Rapid Manufactured Ventilator Specification (RMVS) devised by the Medicines & Healthcare products Regulatory Agency (MHRA), to address the current requirements.

Looking forward, Stewart is excited to see the company expand further into the Medical sector “using our engineering principles to think beyond the traditional, our innovative thinking and digital capabilities, we will not only make great advances in the technology offered but we will be changing people’s lives”

MetLase thrives on offering bespoke problem solving solutions. The team takes time in working closely with each customer to provide a solution that can often take the risk out of new product innovation and provide a safe environment to develop Industry 4.0 digital capability.

An exciting future is on the horizon Stewart and the MetLase team.

To read more about the Ventilator challenge, CLICK HERE

How do you flex your manufacturing to respond to COVID-19 and reshoring needs?

News / By Jenny

How do you flex your manufacturing to respond to COVID-19 and reshoring needs?

Industry hasn’t really seen anything like the sudden changes the pandemic has thrust upon it, and there is now a massive need for manufacturing to be more flexible and rapidly adapt to a changing economic picture.

Horizontal innovation, where we take core technology and processes developed in one sector and transfer them to deliver a solution in another, is very much in demand.

MetLase, which is part of Unipart Group, alongside Instrumentel and Park Signalling, specialises in the manufacture of world-class tooling, intelligent fixturing and components, bringing lead times of months down to hours or days. Faster, more intelligent manufacturing that delivers data is what industry is demanding and MetLase is at the forefront of how we can turn a traditional fixture or tool into an intelligent component, using unique, patented innovative technologies that are transforming manufacturing.

Completed Projects

MetLase has already completed a number of high-profile projects using its rapid tooling development.

This includes creating an aerospace pipe fixture in less than 24 hours, using parametric CAD modelling to modify a composite wing fixture for F1 in just 12 hours and responding quickly to a premium British automotive manufacturer’s styling department change that saw it accommodate quad pipes instead of twin, on a rear exhaust assembly automated laser welding fixture.

The company, which played a key role in the VentilatorChallengeUKConsortium, has also just delivered its largest ever tool, measuring 4 metres in diameter and 2 metres tall.

Despite the scale of the project, manufacturing sign-off and delivery was completed in just one month. Previously, the client would have expected it to take half a year.

Through a series of Manufacturing Masterclass Webinars, MetLase is demonstrating that there has been a huge shift in how tooling and manufacturing is undertaken – and showing that it is possible to re-shore manufacturing using new approaches.

The company currently employs 30 people at its facility on the AMP Technology Centre in Sheffield and works across automotive, aerospace and, increasingly, in scientific equipment and pharmaceuticals, with over £1m of new contracts secured in the UK, Australia, the EU and the US.

Rapid Reaction

News / By Jenny

Rapid Reaction

Reducing lead times and increasing design flexibility are just two of the benefits offered by rapid tooling, a manufacturing process proving increasingly popular with companies looking to improve efficiencies and be first to market with new products. Richard Gould, Business Development Manager of MetLase, explains how his firm are leading the rest of the world in this approach.

Speed is of the essence. It’s a popular phrase and one taking increasing precedence in this globally competitive manufacturing world firms find themselves in. Whether it’s supplying just-in-time for car manufacturers, developing safety critical components for aerospace or being first to market with a new product, the demand for shorter lead-times is growing.

The design and manufacture of tooling is one sector of industry that, to date, has been immune to this change, with a lot of companies happy to factor in many months for the development and delivery of fixtures used in assembly, machining and inspection. Well that could be about to change thanks to the efforts of a Yorkshire-based manufacturing specialist that has introduced a transformative approach to the rapid development of tooling, reducing production time from months to weeks and, in some instances, just a few days.

Transforming the tooling landscape

MetLase, a joint venture between Rolls-Royce and Unipart, is rewriting the rule books when it comes to this critical discipline of engineering, and industry is responding with a surge of orders.

Over the last twelve months, the business has developed an approach harnessing the design skills of a 25-strong engineering team and unique joining solutions that replace the traditional welding process – the latter is apparently top secret and not even customers are given all of the details.

This is reinforced by significant investment at its AMP Technology Centre home to give its experts access to state-of-the-art laser cutting and press brake capabilities.

“The traditional tooling approach is that you take a massive block of material and then you machine away the bits you don’t want to form the tool,” explained Richard Gould, Business Development Manager at MetLase.

“We take a different stance, basically laser cutting sheet metal, usually stainless steel or titanium, into lots of different elements. These are then joined together to form the tool using our very own manufacturing technique, removing the need to weld them together and the distortion that usually comes with this approach.”

He continued: “Everything is controlled ‘in-house’ at MetLase and that’s another big benefit as we control the entire process. We have all the technology we require, we have the engineering talent and we are always adding to our standardised feature library and parametric modelling system that will allow us to instantly access formula for creating tools for specific applications.

“All of this means we are able to work with customers to reduce lead times to weeks, meaning the client has more time to iterate their component design before signing off the tooling.

“As well as the time saving, our service can also help mitigate massive financial costs associated with last minute changes.”

Reducing lead times

MetLase has already completed a number of high-profile projects using its rapid tooling development.

This includes creating a pipe fixture in less than 24 hours, using parametric modelling to modify a composite wing fixture for F1 in just 12 hours and responding quickly to a premium British automotive manufacturer’s styling department change that saw it accommodate quad pipes instead of twin.

The company, which played a key role in the VentilatorChallengeUKConsortium, has also just delivered its largest ever tool, measuring 4 metres in diameter and capable of holding a component 2 metres tall.

Despite the scale of the project, manufacturing sign-off and delivery was completed in just one month. Previously, the client would have expected it to take half a year.

Richard picked up the story: “Interest has come from automotive and aerospace initially, but we are now seeing other sectors, such as construction and medical, exploring rapid tooling and the benefits that can give them.

“Our engineers work best when we have a blank sheet of paper in front of us. This gives them the freedom to listen to the client and what they want the tooling to achieve and then develop a solution that surpasses the brief.

“The MetLase approach means the design engineer you first talk to will actually oversee the entire project, often completing the manufacturing of the tool themselves. Unlike traditional processes, we can also test ideas out relatively quickly by developing prototype tooling at little cost before agreeing full production.

“It can also be a crucial lifeline for companies looking to ramp up production or create new manufacturing cells quickly. Our rapid tooling service means we can take that headache away from them, leaving them free to concentrate on other business critical activities safe in the knowledge their tool or tools will arrive weeks ahead of when they were initially expecting.”

Competing with 3D printing

There has been a lot of talk about this type of manufacturing being faster than 3D printing, and as Richard is quick to point out, in many respects, it is far quicker.

However, he also cites the fact each process is different and to compare the two manufacturing methods is generally very difficult. In fact, MetLase itself uses additive layer components within its solutions where it fits, usually in non-critical areas.

“It’s an interesting argument to have,” admitted Richard. “I prefer to see them as different and sometimes complementary options, each with their own benefits and cost savings. What we have done is moved rapid tooling into the realm of conversation with 3D printing, and this has only been possible by the speed with which we can deliver.

“We wouldn’t have been having this conversation 12 months ago.”

The Drive of their Lives!

News / By Jenny

The Drive of their Lives!

20th August 2020

The very best University educations take place as much in the world of commerce as they do in the lecture theatre. For the last four years MetLase has been part of the development of The University of Sheffield’s Formula Student team ‘Sheffield Formula Racing’.

The Formula Racing initiative is designed to give students experience in ‘real world’ design and development – right from the initial concept through to racing their car in an event with over 80 other cars. It’s this level of personal investment in working to succeed as a team that makes the initiative so exciting.

Tom Nalson, Mechanical Engineer Undergraduate, said “Every year we have 40-50 students involved in our team and we like to choose talented team-players who will benefit the most from the experience and who can demonstrate written as well as practical excellence.”

The team is drawn from all years. Predominantly Mechanical Engineering, but also including Aerospace Engineering, Material Science, Electrical Engineering, and General Engineering. Out of 100 who apply each year, 10-15 new people join the team from the intake – and stay on the team until they finish the degree.

The events where the vehicle competes takes place in the UK at Silverstone and also at the TT Circuit in Assen in 2021 – although the Pandemic may postpone the trip to Europe.

Tom continued “For the competition we have to build, test, drive and compete with the car – a small single-seater. Sponsorship is really important not just for materials, but in helping with engineering. For SFR11 (the team’s current car) MetLase has been heavily involved in the chassis development (a complex spaceframe made from steel tubes) using MetLase jigging.”

Richard Gould, Sales and Business Development Manager at MetLase said “More than one of the team has worked at MetLase in their careers following graduation, including George Packham who still works here. Spending time at MetLase means that the team gets a great insight into the designing process – learning ‘on the job’ from our experienced engineers – and our engineers get to be involved in a thrilling technology!”.

This two-way engagement gives the students an ‘edge’ in their studies – “It’s great experience that makes us more attractive to employees and helps us with the practical end of our studies that perfectly supports our education”, Tom added.

In 2019 the team achieved 14th place with SFR10. For SFR11 in 2021, the team is aiming to be in the top 10 at Silverstone and Assen – and hope to be the best UK team.

We wish the team every success and will be rooting for them to win in 2021.

MetLase chief urges industry to ‘flex’ its technologies to support Covid-19 recovery

News / By Richard

MetLase chief urges industry to ‘flex’ its technologies to support Covid-19 recovery

Creating flexible manufacturing facilities will support the industry’s recovery from Covid-19 according to the head of one of the UK’s leading engineering experts.

Steve Dunn, Managing Director of Rolls-Royce and Unipart joint venture business MetLase, believes the firm’s pioneering work in the Ventilator Challenge UK consortium highlights how technology proven in the aerospace sector has been used in other sectors to help build the country’s manufacturing resilience and support reshoring activities that are slowly picking up pace.

The experienced engineer says the rapid deployment of adaptive manufacturing processes enables companies to reconfigure their factories to keep their workforces safe, accelerate and standardise training and processes and support diversification into new sectors to mitigate unprecedented drops in volumes.

The rallying call comes after his firm played a pivotal role in the nationwide effort to produce more ventilators for the NHS, providing critical design and manufacturability support for consortium partners and production of 72 bespoke manufacturing workstations for Rolls-Royce’s Bristol facility.

These were produced in just ten days, which was significantly faster than it was going to take to purchase and install standard benches.

“Industry hasn’t really seen anything like the sudden changes the pandemic has thrust upon it, and there is now a massive need for manufacturing to be more flexible and rapidly adapt to a changing economic picture,” explained Steve.

“Horizontal innovation, where we take core technology and processes developed in one sector and transfer them to deliver a solution in another, is very much in demand.

He continued: “This is supported by an outstanding engineering team that we can mobilise quickly, with more than 500 years’ knowledge and experience between them – a very powerful source of competitive edge and one we are now putting to good use with exciting new projects in automotive and medical.”

It is also seeing significant growth in the need for tailored digital solutions and in-fixture automation, giving manufacturers essential data at all stages of the processes, enabling continuous improvement, machine learning and artificial intelligence.

“Faster, more intelligent manufacturing that delivers data is what industry is demanding and we are at the forefront of how we can turn a traditional fixture or tool into an intelligent component,” added Steve.

MetLase is hosting a special webinar to support manufacturers to increase their resilience and ability to adapt to the current situation so they can recover from Covid-19. This will be held live on 30^th July at 3pm GMT and you can register to attend at https://bit.ly/flexiblemanufacturingFor further information, please visit www.metlase.com or follow @metlase on twitter

Read the full article here

The Manufacturer cites MetLase as a good example that shows UK manufacturing is as buoyant as ever

News / By Darren Webber

The Manufacturer cites MetLase as a good example that shows UK manufacturing is as buoyant as ever

Following the recent announcement to become the tooling and fixturing partner for Boeing Sheffield’s new manufacturing facility, MetLase are proud to be recognised by The Manufacturer as evidence that the UK’s manufacturing sector is as “buoyant as ever”.

Read the full article here

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