Popular Pages

Manufacturing for the Healthcare Sector

Manufacturing for a wide variety of sectors is one of the reasons we can call ourselves an industry leader.

From agriculture to healthcare, we have the knowledge and technology to precisely schedule and meet our customers’ project requirements.

At Alpha Manufacturing, we understand and prioritise the importance of producing highly versatile products for the healthcare industry.

We ensure they meet trading standards and adhere to any legislation required to be fully functional and appropriate for medical environments.

From seating to sensory pods, we proudly supply many healthcare and medical providers around the UK.

What Have We Done?

Scanning

Technology, particularly in the form of scanning equipment, is a driving force behind crucial advancements in the healthcare industry.

As it continues to evolve, it empowers healthcare professionals to identify a wider range of previously undetectable issues, revolutionising patient care.

Manufacturing scanning equipment such as X-ray machines requires adherence to industry legislation and, of course, the highest quality to be fit for purpose in a variety of medical settings.

Thanks to our state-of-the-art machinery and technologies, we can manufacture these products with the finest precision and produce an accurate final result, regardless of quantity.

Covid-19 Safety Products

During the challenging COVID-19 pandemic, our team at Alpha Manufacturing worked tirelessly to design, produce, and deliver these critical items for our customers.

From hand sanitiser stations to COVID safety screens, we ensured that during the pandemic, we helped our customers keep everyone that little bit safer.

Frames and Metal Components

We design and manufacture components and frames for a range of products that are supplied to healthcare institutions such as hospitals and care homes, some of which include:

– Adult and children’s reclining chairs

– Reclining beds

– Ward Furniture

– Reception seating

– Dining and other utility structure

Orthopaedic Chairs and Beds

We have been producing orthopaedic chairs and beds for 25 years for one of the UK’s largest manufacturers of adjustable, tailored beds and chairs within the medical sector.

Laboratory Cabinets/ Tables

Since 2020, we have manufactured laboratory cabinets/ tables used in the IVF industry for a world-leading fertility and women’s health company.

Sensory

We design and manufacture immersive multi-sensory hubs offering Personalised Sensory Regulation (PSR) as a new and effective way to regulate people with autism and sensory needs.

We’re here to help

If you’re searching for a manufacturer supplier to produce medical and healthcare sheet metal products, we’ve got the experience and expertise to support you.

Get in touch with our expert team to discuss how we can help you: www.alphamanufacturing.co.uk

Industry 4.0 – Paving the Way for a More Efficient and Dynamic Future in Manufacturing

As a leading subcontractor in sheet metal fabrication in the UK, we are passionate about innovation.

Embracing the latest advancements in technology and software is essential not only to keep pace with automation and Industry 4.0 but also to pave the way for a more efficient and dynamic future in manufacturing.

Leading the Charge in Industry 4.0

Peter Smedley, our programming and automation manager, drives our commitment to staying ahead of technological advancements.

Pete spearheads our efforts in Industry 4.0 and the cutting-edge technologies transforming the manufacturing sector, constantly researching new technologies that Alpha Manufacturing can invest in, ensuring we utilise our state-of-the-art facilities to their fullest potential.

Boosting Productivity with Advanced Automation

At Alpha Manufacturing, we believe that innovation is the key to enhancing productivity and quality. We constantly invest in new software and technology.

The new software enables us to automate the programming process by taking product CAD files and converting them to bend programming files. It can also schedule bend programmes to maximise efficiency by reducing the number of tool changeovers, which are essentially non-value-added operations. This function is called TSO—Tool Setup Optimiser.

This capability not only reduces downtime but also ensures continuous operation, significantly boosting capacity and accelerating product turnover. For our customers, this means faster lead times and larger volumes.

Offline Operations

The ability to operate offline through our Trumpf Boost program is a game-changer for Alpha. Trumpf Boost gives us the ability to programme and schedule fully offline, enabling the press brake to continue to operate fully in production mode. This feature significantly increases our product workload, value-added time, and efficiency.

This flexibility ensures that we can handle larger volumes of work without compromising on quality or efficiency.

Seamless Integration for Total Automation

One of the standout features of our production management software is its ability to cross-link with existing systems.

This seamless integration ensures that all of Alpha’s systems can communicate effectively, allowing for complete automation.

The software links directly to the machines, guaranteeing that every task is executed correctly and up to date.

This streamlined process minimizes errors and maximizes efficiency, ensuring that we deliver high-quality products consistently.

How Industry 4.0 is Transforming Sheet Metal Manufacturing

Now more than ever, technology is developing at a rapid pace.

From artificial intelligence to automation – things have changed a lot since we first set up in 1989.

With ever-advancing technology and equipment in the 21st century, Alpha Manufacturing set out on an ambitious investment programme in 2015 to achieve high levels of factory automation.

Often referred to as Industry 4.0 and Smart Factories – the integration of intelligent digital technologies into manufacturing and industrial is game changing.

With a huge emphasis on digitalisation and the turning of physical tests or labour-intensive processes into virtual or digital forms, Industry 4.0 aims to add value, increase efficiency, and significantly reduce production timescales.

Why is automation so helpful in manufacturing?

Automation of manufacturing processes, in essence, is a powerful tool for optimising operations, reducing waste, and significantly enhancing efficiency.

It addresses many of the wastes, especially in process accuracy and quality, waiting, transportation, motion, and inventory. Alpha Manufacturing has a very clear vision of lean manufacturing, which has factory automation at its core.

So, how can the sheet metal process be automated?

Automated machine loading and unloading:

Many of Alpha Manufacturing’s current processing machines feature automated systems for loading and unloading raw materials and parts. This both reduces the time an operator spends manually loading and minimises any risk of injury.

Automated storage:

Systems such as STOPA use a system called ‘chaotic storage,’ which doesn’t require a pre-defined space for each item. Instead, it records each item as it passes into or out of storage and knows its exact location at any given moment.

Lights-out operation:

This effectively means that machines can be programmed and left unmanned to continuously process raw materials and parts. This has a huge positive impact on productivity and additionally allows for large volumes to be processed in a shorter time.

Alpha has invested in many industry-leading automation machines over the past few years, such as the Trumpf Robot Welder, Salvagnini Metal folder, the STOPA Storage System – which can store up to 600 tonnes of raw material and WIP, and even an automatic cardboard box maker!

As we move into the future, we are ready to embrace more automation technology, aligning with the growing trend of Industry 4.0. Our main aim is to benefit not only our colleagues but also our customers, ensuring that our products remain at the forefront of technological advancements.

How does the end customer benefit?

By optimising the manufacturing process and reducing waste while simultaneously improving reliability and accuracy, we are able to offer a much more efficient and cost-effective service overall.

The leaner the manufacturing process, the more value the customer gets, combined with more reliable and consistent service levels!

Will automation completely eliminate manual input in manufacturing?

In short, no, absolutely not!

By automating the traditional non-value-added tasks performed by a human (such as lifting, transporting and data processing), we are significantly boosting our productivity. This allows our workforce to focus on more value-added tasks such as performing manufacturing processes, and upskilling themselves, leading to a more efficient and dynamic manufacturing environment.

There will always be a need for human input in manufacturing, with automation being used to ensure this resource is best deployed for maximum production.