Presentation on theme: "Manufacturing Success - 14 March 2012"— Presentation transcript:
1 Manufacturing Success - 14 March 2012 High value manufacturing, an SME Case StudyIan Warrington, Project ManagerMG Sanders Ltd
2 An overview of our capability Contract Case Study-Future Energy “SME`s make up a half of all jobs in the UK and account for half of our GDP” (B2B Int.)An overview of our capabilityContract Case Study-Future Energy
3 Situated in Stone, 30 miles north of Birmingham in Central England. Established 38 yearsUnder new ownership since January 2006:Rubicon Partners Industries LLP.55 employees, T/O £8.5m (2011)7000m2 Engineering & Metallurgical facility
4 Activity Tungsten alloy blending, pressing & vacuum sintering 6 April 2017ActivityTungsten alloy blending, pressing & vacuum sinteringMulti–axis CNC Milling, Turning, Grinding, EDM: Tungsten (W), Refractory and exotic Ni, Fe, Al based alloysPre-production – Prototype ManufactureClean room assemblyHigh Volume Pharmaceutical Valve Stem productionDesign & Manufacture of UHV & VHF Military Antennas‘End of life’ process re-definition and manufactureReverse Engineering & Sub-Contract manufacture◄ Tungsten LB-SRP
8 6 April 2017ActivityMulti–axis CNC Milling, Turning, Grinding, EDM: Tungsten (W), Refractory and exotic Ni, Fe, Al based alloys◄ Tungsten LB-SRP
9 Activity High Volume Pharmaceutical Valve Stem production 6 April 2017High Volume Pharmaceutical Valve Stem productionCirca 1.2m/monthActivity◄ Tungsten LB-SRP
10 Activity Design & Manufacture of Military Broadband Antennas 6 April 2017ActivityDesign & Manufacture of Military Broadband AntennasHF, VHF and UHFBowman Manpack and VehicleElevated or Ground based units◄ Tungsten LB-SRP
11 AEROSPACE Control surfaces Flutter weights Boeing 737/767/777ATR 76Airbus Military
16 Business Development-Access New Markets Identify innovative & technically demanding opportunities, in Tungsten and other exotic materials or processes, that can be commercially exploited to generate incremental high value revenue Focus on materials competence, skills and future markets
17 Business Development – Future Energy The world's largest Fusion tokamak, JET (Joint European Torus), has produced 16 megawatts of fusion power and proved the technical feasibility of fusion using deuterium and tritium, currently considered the most efficient fuels. The challenge now is to prove fusion can work on a power plant scale.1st wall upgrade to the Joint European Torus (JET) – €48m budget – EFDA funded (EU Commission) to evaluate materials for ITER construction Identify tender opportunities -expression of interest
18 Evaluate Plasma surface interaction for ITER materials: Beryllium 6 April 2017Evaluate Plasma surface interaction for ITER materials:BerylliumW-coated CFCInconel + BeBulk W-LBSRPPreviously CFCW Divertor Module - power handling surface.Bulk W-load bearing septum replacement plates for the divertorForm part of the Divertor module to evaluate Tungsten for power handling surfaces.
19 6 April 2017Competencies & skillsValidation of CATIA V/STEP models and provision of full manufacturing drawingsFusion related materials understandingDevelopment of manufacturing processes and techniquesProduction of tooling and jig fixturesComplex 5 axis machiningAccurate, clean assembly of complex geometry items for UHV and demanding environments (JET QUA 500)Comprehensive inspection to CAD models including CMM, Surface Measurement & SPC.
20 Contract Award Time from expression of interest to tender response deadline = 3 months. Complex tender to interpret: CATIA V model, prototype design & materials/technical specification. Open comments & questions circulated to invited tendering companies. As a potential new supplier an audit visit followed tender submission to assess capability. Contract preparation forms, followed by agreement in principle (without prejudice), fixed price & rigid contractual terms (EU Commission), bank guarantee.
21 Contract AwardFormal contract award (12 months + from Expression of Interest) Value: €5.3m Prototypes (including orders outside of contract) to test and allow final design freeze for manufacture. Deliverables & Milestones mutually acceptable & achievable, including payments.
22 6 April 2017Tungsten - LBSRPTungsten LBSRPMGS Tungsten for plasma facing components - independently tested & qualified;
23 50μm reference tolerances 6 April 201750 assemblies / 80Kg each5 exotic materials1,600 parts /assembly80,000 parts totalClean room assembly50μm reference tolerances
28 Business DevelopmentThe next steps : International fusion research is following a roadmap to achieve power generation within 30 years. It focuses on three main projects: ITER – a multinational project (47%) EU, with a €10bn budget that is being built in the south of France. ITER will be a 500 megawatt tokamak (equivalent to a small power plant) and aims to confirm that fusion power will be possible on a commercial scale; IFMIF (International Fusion Materials Irradiation Facility) – a device that will test the materials needed in a fusion power station, planned to operate in parallel with ITER;
30 Business DevelopmentDEMO – a demonstration power plant supplying fusion electricity to the grid. This is being designed now and would be constructed during ITER and IFMIF operation. If successful, it will be followed by the first generation of commercial fusion power stations.We are looking for partners to collaborate in these high value manufacturing opportunities.Thank you for your attention!