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The Machine was disassembled and loaded onto several heavy goods transporters, before being transferred to its new home, where it will continue production.
Having been an integral and reliable part of Alpha’s production plant for a decade and a half, the TBZ has folded tens of thousands of parts since its original installation at Alpha. Although still in good working order, technological advances meant that there were more economical and efficient alternatives available in today’s market.
Investment in the cutting-edge Salvagnini P4 Lean panel bender during 2019 meant that it was time for the TBZ to move on. The Salvagnini offers exceptional productivity, with like-for like parts once produced on the TBZ, now being completed in a quarter of the time and to exceptional quality.
Boasting a host of state-of-the-art features and automaton, the Salvagnini is the market leader in sheet metal panel folding and is already proving to be a sound investment. The TBZ now moves on to pastures new and with luck, the new owners will get another 15 years solid production from it.
The first week of the programme was spent at the JCB academy where the group completed their induction and were introduced to the subjects that they’ll be studying over the next twelve months. During this time, they will spend four days per week studying at the academy and one day with either Alpha or Bri-Stor Systems.
Their study programme will be divided into three-week modules where they will focus on a particular area of engineering. Their first three weeks was spent studying the basics of sheet metal fabrication, providing a solid foundation in understanding manufacturing and engineering processes.
Having hit the ground running, all apprentices have already achieved a level 1 qualification in Health & Safety, following internal training sessions by Bri-Stor Group Head of Health & Safety. They have also spent time learning the fundamentals of business improvement activities with their respective companies, which will eventually see them complete a week long project, implementing changes around the business.
Eight apprentices have joined the Group this year, with an equal split of four for each company. Now in its ninth year, the programme continues to grow year on year and has so far seen a total of ninety-seven young engineers begin their careers with the Group since its inception back in 2010.
Another exciting calendar of projects and events await the first-year apprentices again this year, including the annual Stone Soapbox Derby and another kit-car build. Make sure to check back here for updates on their activities and progress.
A dedicated stainless facility has been designed to house production, which will be segregated from all other production areas to avoid contamination.
At the beginning of 2019, Alpha recognised the opportunity to diversify into stainless product manufacture with demand for stainless components increasing in recent times. A major enquiry from within the food production sector eventually gave Alpha the impetus to green-light a substantial investment into dedicated stainless steel fabrication equipment.
Due to the high level of finish and exacting hygiene standards required in food processing machinery, a sterile production environment was crucial. A self-contained cell was constructed inside the existing factory, utilising floor space vacated in late 2018, when Alpha’s production office was relocated. Access to the area is restricted to the stainless-steel team only, to further reduce any possibility of contamination from mild steel or other materials.
The cell boasts a host of new machinery including a dedicated stainless only press brake, 4 x 6m bead blast room, ring roller, linishing and polishing facilities and manual weld bays. A new specialist team of stainless fabricators has also been recruited to work in the department, dedicated solely to stainless steel production.
Prototyping has been under way over the past few weeks as fabricators perfected and fine tuned their processes. Now, after official sign off from the customer, Alpha will begin full production of their first stainless steel components for supply into the food processing industry. In the space of a few months, Alpha have gone from having no facilities or experience in stainless steel manufacturing, to being capable of producing parts of the highest quality for a global food processing conglomerate.
This latest investment represents a bold step in a new direction for Alpha and again underlines their commitment to growing both the quality and breadth of their service, through investment in new technologies. These new capabilities open up a host of potential new markets and offer an exciting opportunity for Alpha to bolster their customer portfolio over the coming years.
Early Bri-Stor Group branding
Alpha was founded back in September 1989, initially to supply sheet metal components used by sister company Bri-Stor Systems in their commercial vehicle conversions. Today, Alpha is a thriving business in its own right, employing around 150 people and boasting some of the most cutting-edge manufacturing facilities in the UK. Although still producing 100% of Bri-Stors sheet metal products, Alpha is now also sub-contract partners with a wide number of manufacturing companies covering a range of sectors.
Back in 1989, directors of Bri-Stor Systems recognised an opportunity to bring their manufacturing requirements in house, as opposed to sub-contracting their sheet metal supply, hence Alpha Manufacturing was born. Originally based at Hixon Airfield, Alpha offered CNC punching, laser cutting, folding, and welding, all of which had previously been outsourced. Powder coating services were also made available via sister company Atlas Coatings, which operated from the same site. Alongside Alpha and Bri-Stor, Atlas became the third and final component of what is now known as the Bri-Stor Group.
Alpha’s original Hixon airfield industrial estate facilities
During 2000, it was decided that a new leader was needed for the Bri-Stor Group to consolidate and expand upon its successes to that point. In September of that year, Andrew Humphrey was appointed Group Managing Director, bringing a new sense of direction and drive to the group as a whole. This also strengthened the ethos of collaboration and mutual support between the sister companies, which would be crucial to their individual growth over the coming years.
Having outgrown the original site by 2006, Alpha relocated to its current home, just down the road on Pasturefields Lane in Hixon, on a 35-acre site alongside Bri-Stor Systems and Atlas Coatings. The move allowed the company to expand its operations and take its first steps on a journey towards factory automation. A journey which over time, has gathered momentum and taken Alpha to where its stands today as one of the most technologically advanced sheet metal fabricators in the UK.
2006 – Alpha relocate to Pasturefields Lane
One of those early steps involved the installation of a brand new, fully automated powder coating plant, capable of 24/7 lights-out operation. Utilising an innovative 5 stage pre-treatment Oxsilan process, Alpha were now able to offer not only one of the highest quality powder-coat finishes available but also one of the most ecologically friendly. In addition to the new powder coating facility, a new Pullmax 720 CNC punch machine and Bystronic fibre laser cutter were added to the existing plant list, which was transferred over from the Airfield site. Two brand new Mazak CNC machining centres were purchased, allowing the company to also offer precision 3-axis turning and machining for the first time. This increased capacity allowed Alpha to target new sub-contract customers across a number of sectors including automotive, electronics, agriculture, retail, construction and many more.
In 2015, an ambitious 5-year strategy was set out with the goal of doubling Alpha’s turnover to £20 million by 2020. To achieve this, a plan for strategic investment was also outlined to elevate Alpha’s manufacturing facilities to industry leading standards. To date, this plan has seen over £3 million invested in cutting edge automated machinery, including the TruBend Cell 7000 robotic folder, Salvagnini P4 lean panel bender, two TruPunch 5000 machines, a TruLaser 3030 fibre laser cutter and the STOPA automated storage system, with work on an extension to this due to begin early in 2020.
2019 – Cutting edge sheet metal fabrication facilities
As a result, 2018 was a record year for Alpha Manufacturing both in terms of production volume and turnover, with various major long-term contracts secured, which promised an even more successful 2019 and beyond. Alpha’s ever improving level of capabilities and skill set has seen different types of contracts won recently, with much more complex fabrications and assemblies being produced by Alpha today than ever before.
By the end of 2018, it was decided that a Managing Director was needed to further capitalise on Alpha’s success and growth over the previous 5 years. At the start of 2019 Paul Clews was promoted from his role as Operations Director, having been a driving force in implementing the 5-year plan set out in 2015 and influencing much of the company’s recent successes. Andrew Humphrey retained his position as Group Managing Director, overseeing the Bri-Stor Group as a whole, while Simon Webb became Bri-Stor Managing Director.
2019 has continued in the same vein, with a strong orderbook and various exciting new opportunities on the horizon. Further investment has been made in developing a brand-new division of the factory, which will see the company diversify into stainless steel sheet metal fabrication for the first time. A completely new segregated manufacturing centre has been constructed, with full production due to begin by October 2019. This represents another major step for the company and an exciting opportunity to work within new markets.
Bri-Stor Systems, Atlas Powder Coating & Alpha Manufacturing comprise the Bri-Stor Group
From relatively humble beginnings back in 1989, the company is now an industry leader in its field, boasting some of the most advanced manufacturing facilities, combined with an expert experienced workforce. The future is now very bright for Alpha Manufacturing thanks to a strong commitment to delivering an industry leading sheet metal fabrication service. Consistent investment has equipped the company with cutting edge facilities, while development of its employees has ensured that the right people continue to drive its growth.
Organised by one of Alphas customers, the tournament pitched various local suppliers against each other at nearby Pulse centre in Wednesbury. Having battled through to the semi final stage, Alpha were eventually beaten 2-1 in a hard-fought game. The team ultimately took 3rd place after winning a play-off game, earning them a trophy at the post game presentation.
The event was a complete success and aside from a few achy limbs around the Alpha offices, everybody enjoyed the event. The Alpha team now plan to continue playing regularly and look forward to the opportunity to improve on 3rd at the next event.
The young engineers spent the day familiarising themselves with the Bri-Stor and Alpha facilities and apprenticeship programme in general. Having received their PPE and work equipment, they were given a full guided tour of the site by group apprenticeship manager Will Davies-Hill.
They were also given their induction packs and a breakdown of all the upcoming events and activities that they can expect in their first year, including a week long team building trip to Elan Valley in Wales, as well as the annual Soapbox derby project and other charity events.
The group now have a few weeks to prepare for the beginning of their course, before the official start date of 2nd September.
The event, which takes place over three days, was conceived by Bri-Stor Group directors four years ago as a way of saying “thank you” and giving a little something back to employees for all their hard work throughout the year.
It has proved to be a great success and is now one of the most anticipated work days of the year across the group. Over 200 people will be fed during the course of the three days with Alpha Manufacturing, Bri-Stor Systems and Atlas Coatings employees each having their own BBQ day.
All three are keen cyclists and thoroughly enjoyed the ride, despite the challenging conditions. Rob, who is Alpha’s Commercial Manager commented:
“I’d hoped to complete the ride in a slightly better time but I’s not really what the day is about. We had a thoroughly enjoyed the event and got to see some brilliant costumes plus some weird and wonderful cycles. The torrential rain wasn’t what you’d call ideal conditions for a bike ride but even that didn’t dampen spirits. An all-round good day and great to have done a little in support of the British Heart Foundation.”
Just under 20,000 entrants arrived at the start line in Clapham Common on Sunday 23rd June to take part in the event, which is now in it’s 44th year. Since the event’s inception, elite and novice riders alike have pedalled more than 41 million miles between them and raised more than £70 million. Organisers estimate that this year’s riders raised a combined total of £2million towards various charitable causes.
Simon, Rob and Neil managed to exceed their donation target for the British Heart Foundation and were delighted to take part in the ride in support of the charity. Thanks to everybody who donated and sent messages of support!
Rob Eley – Alpha Commercial Manager, Neil Andrews – Bri-Stor Group Systems Manager and Simon Webb – Bri-Stor Systems Managing Director, will set off from Clapham Common early on Sunday morning, taking the 55-mile route to Brighton beach.
The event will be celebrating its tenth year with this year’s event and is one of the most iconic UK cycle events. Thousands of cyclists, from all ages and experience levels will take part in the ride, raising funds for a wide range of causes.
Rob, Neil and Simon are all keen cyclists, regularly meeting up to cycle routes around nearby Cannock Chase and have been in training for a few weeks ahead of the event. The trio are cycling in support of BHF and are asking for donations in support of the charity. If you’d like to show your support, visit their Just Giving page.
Best of luck Rob, Simon and Neil!
For the third consecutive year, apprentices from both Alpha Manufacturing and Bri-Stor Systems competed in the local event, having designed and built their own racers. Two teams competed in the race but for the first time, teams were mixed from the two sister companies.
On a rainy day in nearby Stone town centre, a timber pirate ship and Only Fools and Horses inspired Robin Reliant lined up at the start line. Although both finished the course in good times, it was the bright yellow Trotters Trading racer that took first place with the fastest downhill time and even managed to catch some serious air over the ramp obstacle.
The Stone Festival and Soapbox Derby have become an important part of our apprenticeship first year program, with the young engineers working in teams to design, build and test their racers. With the entire Alpha and Bri-Stor manufacturing facilities at their disposal, they’re able to test their engineering skills and gain a solid understanding of various manufacturing processes.
Congratulations to both teams on their Soapbox racers and thanks to all involved in organising the Stone Festival.
Back in January, Alpha were announced as team sponsors of the newly formed team, with managing Director Paul Clews keen to support local youth development:
“We do a lot for our young people through our apprenticeship programme through local events, projects and charity activities but this is something a bit different for the wider community. It’s great to be able to help local young people enjoy sports and hopefully they’ll do well in their first season”
The girls secured the first of the two trophies on 11th May after beating Lichfield City 4-1 and completed the double on the 18th May, collecting the Staffordshire Cup Winners Cup. Everyone associated with Leek Town and Alpha are incredibly proud of the Girls’ achievement so soon.
Alpha will continue the young team and wish them every success on and off the pitch during next season.
Purchased as an upgrade to the existing Amada TBZ machine, the P4 Lean Panel Bender takes Alpha’s folding capabilities to another level in terms of productivity, efficiency and flexibility. It also allows Alpha to offer a broader range of product options thanks to its many technologically advanced automated features.
The installation comes as part of a major restructuring of the Alpha factory layout which has also seen office staff relocated to a brand new, modern office and welfare facility. The previous office space, located within the factory has been re-purposed and will become a dedicated stainless-steel sheet metal department.
Other machines have been relocated to accommodate the Salvagnini with long term integration of the panel bender into the STOPA storage system in mind. Full factory automation remains the end-goal for Alpha, with the existing STOPA system set to be extended. The Salvagnini machine, along with various others, will then take raw materials and part-processed products form the tower system before returning it to storage once it’s process is complete, ready for the next process.
Shop floor operatives have now completed an intense period of training, provided by Slavagnini, to ensure that the machine is able to run at maximum capacity. With plenty of new work secured already for the machine, the investment is already beginning to pay dividends.
Pete narrowly lost out during the fight at the Ultra White Collar Boxing event in the King’s Hall Stafford, but thoroughly enjoyed the occasion and was delighted to have raised over £750 for the cause.
“It was an amazing experience and well worth all the training and hard work. I was overwhelmed by all the support I got and donations towards such a worthy cause.”
Prior to the fight, Pete had spent 6 weeks training with other amateur competitors, where he learned boxing basics, sparring and endurance training. Outside of the set training program, he also upped his own fitness training regime in order to be in peak condition.
A massive well done to Pete from everyone here at Alpha Manufacturing!
This will be the “Wildcats” first season, after being formed last year by manager Andrew Rushton, who’s two daughters also play for the team.
Alpha’s Managing Director Paul Clews, who is local to Leek, officially presented the playing kit and waterproof training coats to the young squad and is keen to support local youth development.
“We do a lot for our young people through our apprenticeship programme through local events, projects and charity activities but this is something a bit different for the wider community. It’s great to be able to help local young people enjoy sports and hopefully they’ll do well in their first season”
Leek Town FC, who depend on the support of the local community to operate, were delighted by Alpha’s contribution.
“We would like to say a massive thank you to Alpha Manufacturing for kindly sponsoring Leek Town Girl’s U8 Wildcats strip and waterproof coats. Without sponsorship like this teams would struggle with the increasing costs of strips, training costs and having to purchase equipment.”
Hopefully the new kits will help the Wildcats to a successful first season and everyone at Alpha Manufacturing wishes the girls the best of luck!
Paul will continue to build on Alpha’s recent successes, growing the company as part of the Bri-Stor Group as well as developing its own sub contract customer portfolio.
The appointment comes as part of a wider strategic re-structuring across the Bri-Stor Group which will also see Simon Webb become Bri-Stor Systems Managing Director. Group Managing Director Andrew Humphrey will retain his position with Paul and Simon reporting into him.
The appointments reflect the outstanding growth of the respective companies over recent years and allows both Alpha Manufacturing and Bri-Stor Systems to fully capitalise on solid foundations through individual stewardship, whilst still retaining a Group focus through Andrew’s leadership.
For Paul, this latest appointment is the culmination of a rapid career assent since joining Alpha Manufacturing 9 years ago. Having started out as an apprentice engineer with another midlands-based manufacturer, Paul went on to become design engineer, production engineering manager and eventually manufacturing manager over a 17-year period, before making the switch to Alpha in 2010.
Originally bought to Alpha as manufacturing manager, he quickly set about improving all aspects of production and such was Paul’s impact on the company, having introduced lean manufacturing principles and a dedicated professional ethos, he was appointed Operations Director in 2014.
Again, Paul excelled in this role, leading the company to record turnover and award-winning service levels. After nearly 5 years in this role, it was decided that Paul would be the ideal candidate to lead Alpha’s continued evolution over the coming years.
Paul commented on the key objectives in the coming years and vision for the company overall:
“My primary focus is to deliver our 2020 vision, this is our five-year plan that will see us double the turnover as was in 2015, whilst also achieving world class levels of service to our customers. In line with our business goals we will continue to develop our manufacturing facilities with state-of-the-art automated equipment, underpinning our position as one of the most technically advanced Sheet metal facilities in the country.
Developing the engineering knowledge within our workforce is key to our success, we will further improve the training we give to our current employees and increase our intake of engineering apprentices to ensure we continue to have a robust engineering knowledge base within our business.”
Staff and employees are currently settling into a new £600k modern office and welfare facility, completed late in 2018, while 2019 is already looking extremely bright for the precision sheet metal fabricators, with excellent sales forecast and various developments planned throughout the year.
Final preparations are underway ahead of a £1 million installation of a brand-new Salvagnini P4 Lean panel bender which will bolster Alpha’s existing CNC fold department. In addition, detailed plans are currently being finalised which will see a dedicated stainless-steel fabrication cell added to existing factory facilities.
