Service company moves into CNC machining too

Having begun in business supplying machinery ancillaries and spares, a service company found it was subcontracting out much machining, until it decided to set up its own CNC facilities.
If it's a fast response that's needed, look no further than Replacement and Maintenance Supplies of Alfreton, Derbyshire where, according to Andy Douthwaite and John Whelan, 'we don1t know what to expect from the time we come in to the time we go home'. But whatever it is, one thing is certain: 'When a production line is down because of, say, a broken shaft, the customer wants an immediate response'. Before setting up the business in 1987, both directors were involved with the specialist bearing side of Unipart and this explains why, initially, Replacement and Maintenance Supplies was wholly focused on supplying bearings and related power transmission products such as gears, seals, pulleys, bushes and belting.

Today, however, it also offers a comprehensive machining service tailored specifically to repair work.

Although the company has an off-line programming capability, most of the programming takes place on the machine.

That's why a Proturn VL 425 manual/CNC lathe supplied and installed several months ago by XYZ Machine Tools has become a firm favourite, and has now been joined by a XYZ SM 4000 manual/CNC bed mill.

Both machines are equipped with the innovative Prototrak control that makes switching between manual and CNC operation on the same set-up straightforward and fast.

'The software is brilliant and it's ideal for one-offs,' says Andy Douthwaite, 'Before we set up the machine shop three years ago, we were placing quite of a lot of work with local engineering companies and I noticed they were using XYZ machines.

Having followed their example, I am enjoying the benefits because the new machines are quick to set-up and this business is all about speed.' The 10HP/7.5kW Proturn VL 425 high-speed gap bed lathe already installed is available with either 1.25m or 2m between centres, and features an 80mm spindle bore and spindle speeds from 15 to 2500 rpm.

Constant surface speed is also standard, courtesy of the VL control that provides custom-designed screens to make every operation - whether a clearance cycle, profiling or drilling routines, or standard and custom threads - follow in a logical and clear sequence.

Unlike other CNCs, all the operator is required to do is to define the part geometry and stock dimensions.

From these inputs the toolpath, including all roughing passes and the speeds and feeds, is generated.

The emphasis on breakdown work at Replacement and Maintenance Supplies dictates a high level of individual skill and equipment that is both versatile and easy to use.

'Quantities are usually one to five-offs and most of the time we are working without drawings,' says Andy Douthwaite.

'So we only recruit highly skilled people who can deal with a job from start to finish.

This means liasing directly with the customer, measuring up on site where necessary, using every aspect of our machining facilities, including MIG/TIG welding, inspecting the end result and, above all, knowing that, once installed, the replacement part will have the customer up and running in the shortest possible time.' Since speed is of the essence, the company tends to restrict its activities to relatively local customers and refuses for the most part to quote for production-type work that could restrict the flexibility of its machining operation.

But, says Douthwaite, 'we are always re-inventing ourselves and this brings us into contact with new customers.

If, for example, we are asked to machine a replacement impeller, we develop a new skill and we then look to where we can offer that particular expertise.