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At Alpha Manufacturing, we strive to be at the forefront of innovation in the UK sheet metal fabrication industry. One key factor in our continued success is the strength of our expert programming team, whose dedication and expertise drive the automation processes that enhance efficiency, precision, and productivity.
The Backbone of Automation
Automation is transforming manufacturing, and our programming team plays a pivotal role in making it a reality. From programming CNC punches and laser machines to optimising material utilisation and troubleshooting automation systems, our team ensures that our advanced machinery operates seamlessly. Their ability to translate complex designs into precise manufacturing programmes allows us to deliver high-quality products with minimal waste consistently.
Andrew Hughes, Programming Team Leader, highlights the importance of automation in modern manufacturing: “Automation is only as strong as the programming behind it. When our machines run efficiently, they are capable of full automation, reducing waste and maximising output. Our job is to ensure every programme gets the best out of the technology available.” With 20 years of experience in manufacturing and extensive knowledge of Trumpf Machinery and Stopa Storage systems, Andrew brings invaluable expertise to our team.
Leading Automation at Alpha Manufacturing
Guiding this dynamic department is Peter Smedley, Programming and Automation Manager. With a strong background in both management and technical training, Peter brings a comprehensive vision to Alpha Manufacturing’s automation journey.
His role involves managing a team of six programmers, ensuring timely programming of jobs, overseeing material management, and driving continuous improvements in automation. His extensive expertise and can-do attitude makes Peter the perfect person to lead innovation from the ground up.
“There’s always something exciting going on,” Peter adds. “With a wide variety of customer needs and continual investment in top-tier machinery, no two days are ever the same. I’m passionate about exploring new ways of working and helping drive Alpha Manufacturing toward Industry 4.0.”
Expertise that Powers Innovation
Our programmers are skilled in a variety of cutting-edge software solutions, including Radan and Boost, which are used to create programmes for our lasers, routers, and punch machines. Nathan Grice, an Apprentice Programmer, highlights the dynamic nature of his role: “Every day is different, which keeps things exciting. We work with a wide range of customers and products, so there’s always something new to learn. It challenges us to think creatively and improve our capabilities.” Nathan, an Apprentice of the Year finalist at the 2024 Business Awards for East Staffordshire and South Derbyshire, represents the next generation of programming talent at Alpha Manufacturing.
With over 20 years of experience, Josue Verueco has developed a deep understanding of automation programming. “Programming is the backbone of automation. What we do directly impacts the performance of our machines and the quality of the products we manufacture. I take great satisfaction in creating systematic, efficient, and productive programmes, drawing on my two decades of experience in automation.” Josue’s extensive training in Salvagnini, Bend Cell, and Boost programming ensures that our automated systems function at peak efficiency.
Continuous Learning and Growth
Training and development are integral at Alpha Manufacturing. Stephen Fleet, who has been programming since 2016, highlights the importance of hands-on learning and knowledge sharing between our team: “Over the years, I’ve gained and shared a wealth of knowledge and experience with colleagues. Alpha Manufacturing is always investing in cutting-edge machinery, which gives the team the opportunity to keep up with the latest skills and techniques in manufacturing.”
Andy Dronfield, another key member of our programming team, recently completed advanced Boost training at Trumpf. His role involves ensuring optimal material utilisation: “A key part of my job is making sure we use as much material as possible with minimal waste. It’s not just about efficiency – it’s about making our operations more sustainable and cost-effective.”
Passion Beyond the Factory Floor
While our programmers are dedicated to automation and innovation, they also have diverse interests outside of work. Whether it’s Nathan’s passion for 3D printing and clay pigeon shooting, Stephen’s love for car restoration, Josue’s competitive darts league, or Andrew’s weekend motorbike rides, our team members bring a unique blend of skills and creativity to their roles. Their enthusiasm and problem-solving abilities extend beyond the factory floor, reinforcing the culture of innovation at Alpha Manufacturing.
Pioneering the Future of Automation
At Alpha Manufacturing, we are proactive, ensuring that we’re at the forefront of the latest automation tools. Our expert programming team is at the heart of our automation strategy, ensuring we remain a leader in the UK sheet metal fabrication industry.
With our teams dedication, expertise, and continuous drive for improvement, we’re ready to pass on the latest manufacturing innovation benefits to our customers.
Interested in how our investment in automation and innovation can help your project? Get in touch with our team here: http://www.alphamanufacturing.co.uk/enquiries
At Alpha Manufacturing, we believe that outstanding manufacturing customer service doesn’t stop at onboarding. It’s about building partnerships that last and delivering value every step of the way.
From the moment you join us as a customer, our team is dedicated to ensuring you have the best possible experience, grounded in trust, collaboration, and technical expertise.
Sales Managers who know Alpha Manufacturing inside out
What sets our sales team apart? Corey Hammond and Rhys Smith, two former apprentices, are part of the driving force behind our customer success.
Having grown through the ranks of Alpha Manufacturing, they know our business inside out—from the shop floor to the boardroom. With engineering backgrounds, Corey and Rhys understand the challenges our customers face and are perfectly positioned to offer solutions that work.
Your Success Is Our Priority
At Alpha Manufacturing, we genuinely value our customers. That’s why we go the extra mile to ensure our partnerships are built on mutual success. Here’s how we make it happen:
Customer Service That Works for You
At Alpha Manufacturing, our goal is simple: to provide a level of customer service that makes you feel supported, valued, and confident in your choice to work with us.
Come and see for yourself why so many businesses choose Alpha Manufacturing. Whether it’s a tour of our facility, a collaborative design session, or a quick phone call to address a question, we’re here for you every step of the way.
Interested in kick starting your project? Click here to get in touch with our team.
If you’d like to get in touch with our Sales Managers directly, click to contact Rhys Smith or Corey Hammond.
Cubbie, a personalised sensory space designed by ex-industrial designer David McIntyre, started as a solution to a problem he observed firsthand. As a father of four, two of whom are autistic, David noticed that traditional sensory rooms were often generic and fell short of meeting individual needs. Driven by his family’s experience, he began developing Cubbie in his garage, envisioning a system that could genuinely help people manage sensory stress through customisable, personalised programmes.
Cubbie is now the first product in its field where occupational therapists create tailored, immersive sensory experiences for individuals with autism or sensory sensitivities. Through a system called the “Cubbie Cloud,” users can access their unique sensory programmes from any Cubbie unit, whether they’re at school, in a clinic, or in other sensory-sensitive environments. Since its launch in 2021, the concept has taken off. Over 200 Cubbies are already in place across the UK and Ireland, particularly in schools and healthcare facilities.
As exciting as this growth has been, it has also brought some challenges typical of a start-up. To meet rising demand, Cubbie needed a manufacturing partner that could keep up with rapid turnaround times to maintain cash flow, manage stock inventory, and adapt for various settings. A local manufacturing partner was essential to avoid the headaches and costs of extensive shipping. On top of that, Cubbie’s modular design required a manufacturing partner with the flexibility to adapt the product for a range of environments.
This is where Alpha Manufacturing stepped in. Based in the Midlands, Alpha Manufacturing was ideally located to assist with logistics and offer a fully integrated solution. Cubbie’s design calls for a complex production process, involving both mechanical and electrical assembly, as well as custom wraps for each unit. Alpha Manufacturing could handle everything from raw materials to final assembly in-house, including the application of custom wraps on-site by their sister company, HEX Graphics. This setup made Cubbie’s operations much smoother and faster.
Working with Alpha Manufacturing enabled Cubbie to achieve a quick turnaround for each unit, a huge win for a start-up trying to keep pace with demand and control cash flow. With this efficiency, Cubbie could hold a modest quantity of stock units at their headquarters in Ireland, ready to ship as soon as needed. The partnership has gone beyond just logistics. Cubbie found a team they could rely on, always ready to provide advice, troubleshoot, or make last-minute changes to meet the needs of their growing customer base. The Alpha team’s expertise, particularly on specific adjustments and improvements, proved invaluable as Cubbie’s product continued to evolve.
Reflecting on the partnership, Cubbie’s Business Manager, Erin Rowley, shared, “Working with Alpha Manufacturing has been transformative for us. Their expertise and commitment to quality give us confidence that every Cubbie meets our standards, and their rapid turnaround keeps us on track as we grow. They truly go above and beyond for us.”
Robin Eley, Alpha’s Commercial Director, commented, “This ongoing project touches every part of our hugely diverse range of services, from laser cutting through to powder coating, sub-assembly, graphics printing, and even in-house manufacture of cardboard packaging. It is a tremendous example of our full in-house manufacturing approach to deliver a fully packaged product.”
Looking to the future, Cubbie has big plans. They’re aiming to expand across Europe and other continents, with their products already on their way to Brussels. With Alpha Manufacturing’s support, they’re excited to bring Cubbie’s impact to more people around the world, helping neurodivergent and neurotypical individuals alike manage their sensory needs in ways that make a real difference.
At Alpha Manufacturing, quality isn’t just a department; it’s a cornerstone of everything we do. And for Libby Mellor, a passionate and dedicated member of our quality department, it’s a career path she’s determined to excel in through our Accelerate programme.
Already making strides in the quality team, Libby is seizing every opportunity the programme offers to deepen her expertise and broaden her perspective. Her ambition? To enhance Alpha Manufacturing’s quality processes and build the skills and confidence needed to become a future team leader in this critical area.
One of the exciting aspects of Libby’s journey so far has been working closely with the sales team, stepping outside the factory and into the field. She’s been meeting with customers and potential clients, learning firsthand about their quality expectations and processes.
“This experience has been invaluable,” Libby shared. “It’s given me a much clearer understanding of what our customers need from us quality-wise and how we can continue to build strong, collaborative relationships with their teams.”
After completing her first customer visit, Libby is enthusiastic about the road ahead. She’s already gathering insights and ideas to bring back to Alpha Manufacturing, identifying opportunities to refine and enhance our quality standards to better meet customer demands.
As part of her ongoing development in the Accelerate programme, Libby is also taking on the Lean Six Sigma Combined White, Yellow, and Green Belt course. This specialised training, provided by BSI Group, offers her an in-depth understanding of process improvement methodologies, empowering Libby to enhance quality across the board. In completing this course, Libby is strengthening her ability to identify and eliminate inefficiencies, reduce variation, and drive continuous improvement within Alpha Manufacturing.
The Accelerate programme isn’t just about technical expertise – it’s about building well-rounded leaders. That’s why Libby also participates in our Leadership development programme, a key part of her development journey.
Through this programme, she’s honing critical management skills, growing her self-confidence, and learning to make effective decisions – skills that will serve her well as she progresses toward her goal of leading Alpha’s quality team.
With a clear vision for her future and the resources to help her achieve it, Libby’s journey is a testament to the value of investing in our people. The Accelerate programme is about unlocking potential, and Libby is a shining example of what happens when talent meets opportunity.
At Alpha Manufacturing, we’re proud to have Libby as part of our Accelerate cohort, driving innovation and excellence in quality. We can’t wait to see what she achieves!
At Alpha Manufacturing, we are proud to be recognised as one of the UK’s leading sheet metal fabricators, delivering exceptional integrated electrical solutions across a diverse range of industries.
Our expertise ensures we provide customers with a comprehensive service, from design and fabrication to the seamless integration of complex electrical components, all under one roof.
Our state-of-the-art facilities allow us to manage every stage of the manufacturing process in-house, ensuring unparalleled quality and efficiency. From initial design and prototyping to precision sheet metal fabrication, electrical assembly, and final finishing, our vertically integrated approach guarantees total control over production timelines and quality standards.
To meet the growing demand for fully assembled products, we have established a dedicated assembly facility known as Alpha Integrated Solutions, located in Hixon, Staffordshire. This division works closely with both new and existing customers to develop complete products that combine components manufactured by Alpha Manufacturing and other suppliers. By offering complex assembly services, we provide significant cost and efficiency savings to our clients.
Alpha Manufacturing excels in incorporating advanced electrical systems within our sheet metal fabrications. Our expertise includes integrating touchscreen interfaces in kiosks, technology in library book return systems, and sensory equipment for specialist pods designed to support individuals with additional needs. We ensure every electrical component is seamlessly embedded, tested, and fully operational upon delivery, providing a complete, end-to-end service.
As a UK market leader, we understand the importance of tailored solutions. We collaborate closely with our clients to deliver customised sheet metal products with expertly integrated electrical systems. Our wide-ranging experience covers various sectors, ensuring we bring innovative ideas and best practices to every project.
Quality sits at the core of everything we do. Our dedicated assembly facility, Alpha Integrated Solutions, is staffed by highly skilled professionals who uphold the highest standards in both sheet metal fabrication and electrical assembly. We continually invest in the latest technology, training, and processes to ensure we remain at the forefront of the UK manufacturing industry.
Choosing Alpha Manufacturing means partnering with a trusted UK leader in sheet metal fabrication and integrated electrical solutions. Our comprehensive services, cutting-edge technology, and unwavering commitment to customer satisfaction make us the ideal choice for your next project.
To find out more or to discuss your specific requirements, get in touch with our expert team today.
We are immensely proud to have our own in-house powder coating plant, Atlas Coatings, at The HEX Group.
Committed to growing this business division, we are thrilled to introduce Mark Proctor, who joined Atlas Coatings and The HEX Group in September 2024 as Production Manager.
Mark’s career journey began as a Stamping Press operator at Denso Manufacturing. Mark’s drive for excellence and continuous improvement helped him steadily rise through the ranks during his 15 years of service. His dedication and leadership eventually earned him the position of Production Manager, where he successfully oversaw multiple departments and led numerous teams.
During his tenure at Denso, Mark also pursued professional development, achieving several industry qualifications, including a Level 5 Management certification.
After his successful career at Denso, Mark took on a new challenge at 8 Ball, where he honed his management skills and took his leadership to the next level. His time there was marked by impressive achievements, as he implemented new standards and procedures. Reflecting on his time at 8 Ball, Mark says, “My time there allowed me to show my capabilities and restructure the business, resulting in substantial growth.”
Seeking a new challenge, Mark was introduced to powder coating during his move to Pym & Wildsmith, a metal finishing company. Over five years, Mark’s responsibilities grew, culminating in a promotion to Operations Manager. In this role, he embraced the strategic aspects of operations, which he found deeply rewarding.
Now, as Production Manager at Atlas Coatings, Mark is not just a leader, but a passionate advocate for operational excellence and production efficiency in the powder coating sector. He is committed to bringing his experience and fresh perspective to the role, ensuring that Atlas Coatings reaches new heights and delivers the highest quality to our customers.
Mark shared his vision for Atlas Coatings: “There’s significant growth potential in various areas of the powder-coating plant. I’m excited to take a hands-on approach and eager to dive in, push the business forward, and explore new opportunities.”
In his downtime, Mark is a dedicated family man and Manchester United fan. He enjoys socialising with friends and family and has recently taken up learning to play the guitar.
Welcome to the team, Mark. We are excited to see what the future holds for you within The HEX Group. Your experience and passion for excellence will undoubtedly contribute to our continued success.
Meet Maria Sokalska and Magdalena Neizabitowska – a niece and aunt duo working in Alpha Manufacturing.
Manufacturing is often perceived as a male-dominated environment, but at Alpha Manufacturing, we’re proud to employ many women across the business who are tremendously passionate about the work they carry out daily.
Maria and Magdalena work in assembly, constructing server cabinets for one of our largest customers.
Originally from Poland, Magdalena joined the Alpha Manufacturing team two years ago. She comments, “I love my role in assembly, I like the people, and the work hours fit my family life. When a space in the team opened up, I quickly recommended the role to my niece, Maria.
With two sons, Magdalena spends her free time as a mum and supporting her boys.
Maria joined the assembly team six months ago and is enjoying the opportunity. She says, “Although I’ve only been here six months, I’ve been offered an opportunity to train in the quality area, ensuring that all cabinets pass quality inspections before they leave the factory.
“Everyone at Alpha Manufacturing is friendly, helpful, open, and honest. I really like that. I enjoy learning new things and am keen to see how far I can go within the company.”
Maria enjoys hiking, especially in the Lake District and walking her dog, a Pomeranian called Elmo. She’s also a big lover of the gym, something she says helps her in her role as it can be quite manual.
Maria adds, “Assembling the cabinets is a very satisfying job. From seeing the parts flat, to fully constructed is a real sense of achievement.”
Product assembly is not just a task but a crucial part of our business. The dedication and passion of our employees, like Maria and Magdalena, are what ensure it’s done correctly.
Without their commitment to doing a great job, we wouldn’t achieve the outstanding results we do, and the fantastic customer feedback we receive.
In recent years, we’ve witnessed a shift in the manufacturing landscape — a resurgence in onshoring that brings production closer to home.
As supply chains overseas present more barriers and delays with shipping, costs, and regulatory charges, UK-based companies are starting to look closer to home for high-quality manufacturing solutions.
As a proud UK sheet metal fabricator, Alpha Manufacturing stands at the forefront of this movement, offering unparalleled expertise, cutting-edge technology, and a commitment to sustainability.
In this blog, we’ll explore the benefits of onshoring in the UK and why Alpha Manufacturing is the partner of choice.
Why Onshore in the UK?
Resilience in Supply Chains: Recent global events have highlighted the vulnerabilities of extended supply chains. Onshoring manufacturing to the UK significantly reduces these risks, offering more control and flexibility, which is essential in navigating the uncertainties of today’s market.
Quality Assurance: British manufacturing is synonymous with quality. By onshoring, businesses can benefit from the high standards of UK manufacturing regulations, ensuring that their products meet the best quality and safety benchmarks.
Sustainability: Onshoring reduces the carbon footprint associated with long-distance transportation of goods. It aligns with the growing demand for sustainable practices and helps companies contribute to environmental conservation efforts.
Economic Benefits: Investing in local manufacturing supports the UK economy, creates jobs, and fosters innovation. It’s not just about keeping the wheels of industry turning; it’s about fuelling the engine of growth and prosperity across the nation.
Faster Turnaround Times: Proximity matters. Onshoring to the UK means shorter lead times, allowing businesses to respond more quickly to market demands and customer needs.
Why Choose Alpha Manufacturing?
State-of-the-Art Technology: At Alpha Manufacturing, we pride ourselves on our investment in the latest manufacturing technologies. Our facilities are equipped with advanced machinery for precision engineering, ensuring high-quality production for every order.
Expertise and Experience: With years of experience in sheet metal fabrication, our team of skilled engineers bring a wealth of knowledge to every project. Our expertise ensures we can tackle complex challenges and deliver bespoke solutions tailored to our clients’ needs.
Commitment to Sustainability: We understand the importance of sustainable manufacturing practices. Alpha Manufacturing is dedicated to reducing environmental impact through efficient production processes, waste reduction, and energy conservation.
Flexibility and Customisation: Our approach is centred around meeting our client’s unique requirements. Whether it’s small-to-medium runs or large-scale production, we offer flexibility and customisation options to suit any project. Our expert team is always here to help you find the perfect solution.
Collaborative Partnerships: We believe in building strong, collaborative relationships with our clients. By choosing Alpha Manufacturing, you’re not just getting a supplier; you’re gaining a partner committed to your success.
Our combination of technological prowess, world-class expertise, and a commitment to quality and sustainability makes us the perfect partner for any company looking to harness the benefits of UK manufacturing.
In embracing onshoring, you’re not just making a business decision; you’re investing in the future—of British companies, British communities, and British people. Alpha Manufacturing is already leading the charge, helping to shape a resilient, sustainable, and prosperous manufacturing landscape in the UK. Let’s build that future together.
Interested in choosing a UK-based sheet metal fabricator for your manufacturing needs? Get in touch with our team by clicking here.
Great people are a company’s greatest asset. At Alpha Manufacturing, we’re proud to have a passionate, committed, and knowledgeable team that cares about the individuals they manage and support daily.
In March 2023, we took the senior team on a leadership development journey, empowering them with new techniques to get the best results from their functions.
Alpha Manufacturing partnered with local talent, culture and leadership guru Sally Brys from Limitless Development to work with the team to explore new ways of thinking, approaching people and behaviour, and improving department performance.
Sally spent time in the business before planning the training to understand challenges and concerns before producing an engaging, reflective and thought-provoking three-module course for the Alpha Manufacturing team.
Planning Manager, Joanna Sitek, is just one of the Alpha Manufacturing employees who completed the training. She comments, “I have to be honest – I was hesitating at first. Having had a previous disappointing experience with this kind of training course, I thought it might not be for me, but I am one of those people who do not judge before trying it first, so I gave it a go.
“The safe and supportive atmosphere Sally has created encouraged us to take the shield off and be honest about both work-related and personal challenges we experience. One of my personal struggles was always the language barrier, with public speeches being extremely stressful. Therefore, I was avoiding it where I could.
“With the help and support of my group, I understood the barrier I have created in my head for 18 years should no longer be there. Looking back now, it is probably the best decision I have made in a while”.
Nick Moss, Operations Manager, adds, “Being part of the first Leadership Development programme was great, although I was quite sceptical at first. Reflecting on my leadership style and the kind of leader I want to be has helped me identify where I want to be and the part I play in the future of the business. I’m excited to try new coaching techniques to help my team reach their full potential and create a strong team. At Alpha Manufacturing, we have some incredible people, and I’m proud to be able to support them in their growth and development”.
Due to the programme’s success, Sally has tweaked the course content alongside the business to deliver similar training at the team leader level. This allows valued employees to enhance their skills and provide frameworks and models that can be used in the workplace to get better results and improve productivity.
Sally Brys, Limitless Development, comments, “The Alpha Manufacturing leadership programme is a deliberate investment in the organisation’s heart – its people. The programme has been meticulously designed to reflect the needs of the business, to nurture and develop the skills of those who attend and to drive a culture of continuous growth and excellence. It empowers individuals to unlock their full potential, aiming to create a ripple effect that positively impacts those they work with”.
At Alpha Manufacturing, our people are our greatest asset. Without them, we wouldn’t be the business we are today. But we can be better, and with investment in training and supporting employee development and growth, we can achieve even greater things, and we’re incredibly excited about it.
Alpha Manufacturing is your go-to destination for high-quality sheet metal engineering services in the UK.
With a rich history dating back to 1989, we take pride in offering a comprehensive fabrication service that spans from initial concept and design to delivering the final product. Our commitment at every stage of the fabrication process is to produce high-quality parts efficiently, economically, and with a focus on sustainability.
The Role Alpha Manufacturing Plays in Sheet Metal Engineering
For over three decades, Alpha Manufacturing has been a leading provider of sheet metal fabrication services across diverse industry sectors in the UK. Our expertise has been instrumental in supporting manufacturing processes in EV charging, nuclear, construction, alternative energy, heat, automotive, and truck industries, among others.
Our clientele includes companies of all sizes, each contributing significantly to the UK’s economy. What sets us apart as a premier sheet metal fabrication company is our unwavering commitment to the continual growth of our workforce, our visionary approach, industry knowledge, and commitment to innovation.
Exemplary Team of Experienced Engineers
At the heart of our success is our dedicated team of professionals. Our workforce comprises some of the UK’s most skilled, dedicated, knowledgeable, and experienced individuals in all facets of metal fabrication. From innovative design concepts to prototyping, welding, fabrication, and CNC operation, Alpha Manufacturing engineers collaborate to create top-quality products in metal fabrication and precision engineering.
Investing in the Future Generation
We don’t just focus on being the best; we are committed to sharing our knowledge with the next generation of sheet metal fabricators. Alpha Manufacturing takes pride in offering apprenticeships to nurture and develop young minds with a passion for engineering into experienced professionals within the sheet metal industry. Our commitment extends further with The HEX Group’s dedicated training facility, where apprentices can enhance their skills. The accredited apprenticeship program, evolving year on year, reached a milestone in 2023 with our largest cohort to date, showcasing our teams’ passion and dedication.
Cutting-Edge Engineering Technologies
Alpha Manufacturing stands out by utilizing the latest technology and state-of-the-art machinery in all our services. From automation in machining processes using advanced CNC software to designing with up-to-date CAD software and employing revolutionary equipment like the TruBend Cell, Automated Robotic Folder, the Salvagnini P4 Lean Panel Bender, and our latest addition, the Trumpf TruBend 5170S, we remain at the forefront of metal fabrication.
Looking for Expert Metal Fabrication Services?
If you’re in search of expert metal fabrication services, look no further. Contact us, and we’ll be delighted to discuss your requirements.
Trust Alpha Manufacturing for excellence in sheet metal engineering.
Two months into 2024, the manufacturing industry is again facing difficult market conditions, supply chain disruptions and rising costs.
Taking matters into our own hands, we have started the year positively, and despite the challenges, are looking optimistically at the year ahead.
In this article, Sales Director Michael Whitfield outlines the biggest issues facing our industry, and how we’re overcoming them, supporting our customers through unprecedented market volatility.
Supply Chain Disruption
Supply chain disruptions are nothing new. With Brexit, the pandemic and geopolitical tensions all testing the global market in recent years, manufacturing businesses have had to become accustomed to new ways of working. Now, with issues in the Red Sea adding more pressure to import and export markets manufacturers are again facing challenges.
Since the beginning of the year, military activity has been escalating in the Red Sea effecting all trade through the region. Ships carrying anything from clothes and toys, to fabricated parts have been the target of attacks by Houthi rebels, forcing major operators to divert cargo away from the Suez Canal. Adding up to 20 days to journey times, these delays have affected businesses across the UK, driving costs up and leaving some without manufactured parts or products.
Flying the flag for Great British manufacturing, we continue to invest in supply chain integration. With our entire operation based in the UK and very few outsourced processes, we are able to maintain complete control over our manufacturing, reducing shipping reliance and supply chain risk for our customers, while maintaining a high-quality product.
As more and more British businesses look to home to secure their future, we are here to support them. The business climate today, with rising costs and growing uncertainty is difficult enough. If we can support just some of that, reducing reliance on phantom overseas suppliers with invisible customer service, then we’ll be doing our job right. Working with new and existing customers, we offer state-of-the-art services, manufacture innovative products, and meet our customers’ complex requirements.
Skills Gap
Today’s labour market is a challenge for all businesses. The result of Brexit and the pandemic has left a skills shortage across much of the UK manufacturing sector. Recruitment and retention are central to our strategy, and is a key driver for future growth and success. That said, we continue to invest in our people to make Alpha Manufacturing an attractive place to work. Following our recent investment in a cutting-edge Trumpf TruBend 5170S fold machine, we are upskilling several operatives to use our latest machinery. This ensures we maintain our expertise, allowing us to deliver the highest quality products to our customers.
2023/24 also saw our largest intake of apprentices ever, with 18 new apprentices joining across The HEX Group. Since launching our fully accredited apprenticeships in 2010, this has formed a crucial part of our growth strategy and has allowed us to promote careers within our sector. Offering exciting and dynamic programmes, we nurture our young people, offering hands-on learning to produce qualified, ambitious, highly productive colleagues who keep our business moving forward.
Sustainability
Every industry is touched by sustainability and manufacturing is no different. With the drive towards net zero and more environmentally conscious business practices coming to the forefront of all our minds, we have made significant steps to make our processes more sustainable. In 2022, we installed 1770 solar panels covering more than 3500m2 of roof space at our facility in Staffordshire, saving more than 150 tonnes of CO2 emissions each year. We also continue to invest in our future, ensuring we have the latest energy-efficient machinery to reduce our environmental impact. Our latest investment reflects this commitment, offering significant improvements in energy consumption and promoting eco-friendly manufacturing practices.
We are incredibly proud to be a British manufacturer and work tirelessly to maintain our high standards, even in challenging times. We are resilient by nature and continue to work closely with our suppliers to ensure we deliver for our customers.
Having the capability to offer customers a complete range of solutions for welding and fabrication jobs is just one of Alpha Manufacturing’s unique advantages.
In this article, we explore the benefits of manual and robot welding and explains how Alpha customers benefit from this market-leading service.
There are so many processes involved in the fabrication of just one product, but the beauty of an Alpha Manufacturing made component is that every area of our production uses the best available technology for that particular process. There’s no question, certain methods have their unique advantages and welding is no different – not only from a process and application capability but from a value engineering process too.
The manual welding process has great flexibility and can be involved in a wide range of applications. One of the first differences between manual and robot welding is that manual welders are able to work with a variety of different thicknesses and a mix of products using their own skill and knowledge base, rather than requiring a programmer to set up before each use.
This method also means that high complexity can be achieved as manual welders can navigate hard to reach weld sites. One of the unique benefits of manual welding is that it’s the perfect solution for low quantity runs and prototyping, enabling the welder to use their skills and expertise.
But that’s only half of the welding story. At Alpha Manufacturing, arguably we have the most exhaustive robotic welding capability in the UK including the Yaskawa Robotic Welding Machine. Featuring ‘cold metal transfer technology’, our customers have come to rely on world-class weld standards. While manual welding has many advantages, robotic welding delivers consistently high quality output with a high repeatability rate, as the robot follows the exact same programme.
There’s no question, for Alpha customers having the in-house capability to deliver a broad spectrum of weld techniques is just one of the Alpha Manufacturing differences. Whether a component is welded in one of our weld bays by one of our expert weld team or a component is passed through our automated welding machinery, every component manufactured in our Staffordshire production facility achieves the same world-class standard. That’s our commitment to every Alpha Manufacturing customer. It’s what we’re famous for.
A Comparative Look at Manual and Robotic Welding Processes
At Alpha Manufacturing, our commitment to excellence in sheet metal fabrication has been a hallmark of our identity. In this article, we explore the pivotal topic of welding, specifically examining the distinctions between manual welding and our state-of-the-art robotic welding processes. With our cutting-edge machinery and a team of skilled experts, we stand as a leading sheet metal fabricator in the UK, delivering consistently high-quality products to our valued customers.
Manual Welding Excellence
Alpha Manufacturing takes pride in offering a diverse range of welding techniques through our expert manual welding team. Our weld bays, equipped with the latest technology, allow our skilled professionals to bring their expertise to every component. The advantages of manual welding are numerous, including the ability to adapt quickly to various specifications, intricate designs, and unique challenges. The hands-on approach ensures a personalised touch, allowing our team to tailor solutions to meet specific customer needs.
Robotics Precision with ‘Cold Metal Transfer Technology’
Alpha Manufacturing’s commitment to innovation is evident in our automated welding machinery, featuring cutting-edge ‘cold metal transfer technology.’ This technology enhances the precision and efficiency of our robotic welding processes. Unlike manual welding, where the outcome relies on individual skill and technique, robotic welding ensures a consistently high-quality output with an impressive repeatability rate. The robot meticulously follows the exact program, delivering unparalleled precision and uniformity in every weld.
Consistent World-Class Standards
Whether a component is crafted by the skilled hands of our manual weld team or undergoes the meticulous precision of our robotic welding machinery, Alpha Manufacturing guarantees the same world-class standard for every product. Our Staffordshire production facility serves as the epicentre of quality, where every weld is a testament to our dedication to excellence. This commitment is the essence of what sets us apart, and it’s what we are renowned for in the industry.
In the dynamic world of sheet metal fabrication, Alpha Manufacturing continues to redefine standards through a blend of manual expertise and cutting-edge robotic technology. As we progress into 2024, our unwavering commitment to consistently delivering high-quality products remains the cornerstone of our reputation.
Whether it’s the artistry of manual welding or the precision of robotic processes, our customers can rely on Alpha Manufacturing to exceed expectations.
Interested in discussing what we can do for you? Get in touch with our team today.
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Alpha Manufacturing, a proud member of The HEX Group, is excited to announce a £450,000 investment in the acquisition of the cutting-edge Trumpf TruBend 5170S. This state-of-the-art machinery will not only elevate the company’s manufacturing capabilities but also contribute to its commitment to quality, innovation, and environmental sustainability.
The introduction of the Trumpf TruBend 5170S signifies a significant leap forward for Alpha Manufacturing in terms of quality, accuracy, and efficiency.
The key features of the new machinery include:
Automatic Controlled Bending: The Trumpf TruBend 5170S enables automatic controlled bending, ensuring greater precision and quality in the manufacturing process.
3D Programme Folding: Alpha Manufacturing can now leverage 3D programmes for folding, enhancing visual management and further streamlining the production process.
Part Indicator Technology: The machinery is equipped with part indicator technology, preventing incorrect folding and significantly reducing errors, waste, and production time.
Environmental Impact: Alpha Manufacturing’s investment aligns with its commitment to environmental sustainability. The Trumpf TruBend 5170S contributes to the company’s 2037 carbon neutrality goal by reducing energy consumption and promoting eco-friendly manufacturing practices.
Paul Clews, Managing Director at Alpha Manufacturing, expressed enthusiasm about the investment, stating, “The Trumpf TruBend 5170S represents a significant step forward for Alpha Manufacturing, allowing us to deliver even higher quality products while aligning with our environmental goals. This investment reinforces our commitment to providing the best for our customers, our team, and the planet.”
Gerry Jones, Sales Director at TRUMPF, added: “Alpha manufacturing are a key customer in the UK and a forerunner in terms of technical capability, the TruBend 5170 S strengthens their position.”
We look forward to working with Alpha Manufacturing and supporting their exciting progress.”
Benefits for Alpha Manufacturing and Its Stakeholders:
The Trumpf TruBend 5170S brings a host of benefits to Alpha Manufacturing, its dedicated team, and the environment:
✅ Lift Support: The bend support arm of the machinery can handle parts weighing up to 100KG, enhancing efficiency and capacity.
✅ Reduced Manual Handling: Automation and innovative technology minimize the need for manual handling, promoting a safer and more ergonomic work environment.
✅ Energy Efficiency: The new machinery is designed with reduced energy consumption in mind, contributing to Alpha Manufacturing’s sustainability initiatives.
✅ Offline Programming: The Trumpf TruBend 5170S allows for offline programming, providing opportunities to increase machine uptime and overall output.
With great pleasure, we introduce Leo Manifold, a dynamic and ambitious member of our team at Alpha Manufacturing.
Leo joined us in September 2023 as a Higher Degree Apprentice, pursuing a four-year course in Production Engineering. His unique journey to Alpha Manufacturing and outstanding contributions have already set him apart as a rising star within the company.
Leo embarked on his journey with Alpha Manufacturing after completing his 6th-form studies in engineering and business at JCB Academy. Leo’s dedication and skills stood out during his time at JCB Academy, leading him to a 2-week work experience stint with us. This experience showcased Leo’s capabilities and paved the way for an exciting opportunity to join us as a Higher Degree Apprentice. Leo comments on his work experience…
“Work experience at Alpha Manufacturing was great. From day one, I was made to feel part of the team, and the diversity of skills I learnt in just two weeks was incredible.”
Leo’s commitment to his education is commendable. Currently enrolled in a 4-year Higher Degree Apprenticeship programme in Production Engineering, Leo attends college once a week while contributing his freshly acquired knowledge and skills to our projects.
One of Leo’s initial projects involved designing and manufacturing a new product for our HEX Living division. Leo successfully completed this project within an astonishing three months and demonstrated remarkable efficiency and dedication. The prototype is now in our team’s capable hands, and we eagerly anticipate its imminent launch in the coming weeks. Leo discusses this project…
“Being part of the design and manufacturing journey for the new HEX Living product was exciting. It was a privilege for Alpha Manufacturing to put their trust and confidence in me. It was great to see the process from conception to completion”.
Leo’s passion for manufacturing and engineering is evident in every task he undertakes. His enthusiasm is not only limited to his academic pursuits but extends into his work at Alpha Manufacturing. Leo’s drive is not just a professional attribute but a personal one, making him an asset to our team.
Beyond the world of manufacturing, Leo maintains a balanced and active lifestyle. He takes a keen interest in staying fit and healthy, with a particular focus on running and kickboxing.
As Leo embarks on his career journey, we wish him the best of luck! Your hard work and enthusiasm are truly inspiring, and we cannot wait to see where your career at Alpha Manufacturing takes you!
At Alpha Manufacturing, we understand the nuances between manufacturing and fabrication, two distinct yet interconnected processes in the industrial realm. Let’s delve into the differences and highlight our expertise in delivering precision-crafted products.
Fabrication Excellence at Alpha Manufacturing
Fabrication, for us, is an art that involves constructing products by skillfully combining standardised parts through various individual processes. Consider steel fabrication, where we produce metal structures using cutting-edge techniques such as cutting, bending, and assembling. Leveraging computer-aided designs (CAD) and computer numerical control (CNC) technology, we ensure high-quality assemblies with precise dimensions.
Our design experts at Alpha Manufacturing specialise in creating fully assembled prototypes, providing our clients peace of mind. From pre-assembled balcony units for new build apartments to modular utility rooms and beyond, we excel in crafting diverse products. By embracing advanced technologies, we streamline the steel erection process on-site, ensuring cost-effective solutions through optimal material utilisation and faster assembly times.
Manufacturing Excellence at Alpha Manufacturing
Manufacturing is the seamless transformation of raw materials into finished products. It’s a holistic process that encompasses large-scale production, utilizing machinery, tools, and chemical/biological processing. Alpha Manufacturing excels in this sector, offering a start-to-finish process for virtually any sheet metal requirement.
Our expertise spans various industries, including apparel, chemicals, electronics, and more. From design to CNC machining, assembly to delivery, Alpha Manufacturing provides a comprehensive service. We take pride in our ability to oversee the entire production journey, ensuring the highest quality standards.
Bridging the Gap: How We Differ
The key differentiator between manufacturing and fabrication lies in the extent of the process involved. Fabrication focuses on assembling standardised or specialised parts, forming components for the final product. On the other hand, manufacturing is a comprehensive start-to-finish endeavor, encompassing the creation of parts and final assembly.
At Alpha Manufacturing, we seamlessly integrate fabrication into our manufacturing processes, ensuring precision craftsmanship and attention to detail. Our commitment to quality and efficiency sets us apart, making us your trusted partner for intricate projects.
Discover the Alpha Manufacturing advantage—where precision meets perfection in manufacturing and fabrication. Explore a world where every detail matters, and every product is a testament to our unwavering commitment to excellence.
Get in touch with our team to understand how we can help you by clicking here.
