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Bringing Manufacturing Home: Onshoring with Alpha Manufacturing

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.

Sheet Metal Engineering Excellence at Alpha Manufacturing

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.

Meet the Team – Libby Mellor, Trainee Quality Engineer

Twelve months after joining Alpha Manufacturing, after attending the Company’s first recruitment open day, Libby Mellor, a former Mechanical Engineering apprentice, has implemented the iAuditor quality control processes at the new 35,000sq ft Alpha Manufacturing Chemical Technologies site in Stafford.

Libby joined the business as a Trainee Quality Engineer and explains how she established an interest in Quality Control from her Engineering Apprenticeship Programme: “Spending time in various departments gave me a real insight into Engineering. Quality was the one area that particularly captured my interest, realising the importance of inspecting and monitoring operations to ensure they meet production standards.”

Not long into her role, Libby embarked on the challenge of implementing the iAuditor quality inspection system at our new Stafford site in conjunction with INEOS Electrochemical Solutions. Working in a brand-new factory, Libby explains how she tackled the challenge head-on:

“It was great that Alpha saw my potential and gave me this opportunity. In the beginning, the integration of the INEOS control plan into iAuditor was a priority, continually highlighting potential changes and addressing them along the way. Manufacturing of the product had not yet begun, which meant working closely with INEOS was crucial, and ISIRs (Initial Sample Inspection Reports) were key to ensuring quality standards were met. Before production commenced, the quality control process of regular inspections was imperative to achieving such high-precision engineering.

“We have come a long way, and my day-to-day routine focuses primarily on operator training and ensuring all the quality controls we have put in place are adhered to. The iAuditor software is tablet-based and keeps inspections accurate and up-to-date, and the process is simple and quick.”

Once the new site is fully commissioned and handed over, Libby will return to the Quality Department at Alpha, where she has recently been accepted onto the Group’s new Leadership Programme, alongside a Quality Management and Auditing course. Libby’s commitment and enthusiasm for her role and the business are unquestionable, and her future at Alpha is exciting.

Back UK Manufacturing and Boost Britain’s Economy

UK businesses continue to face many struggles and unprecedented challenges during 2022, with the UK’s rising cost of living pressures and inflation jumping to a staggering 13.2%.

Fuel and energy costs remain a huge concern, with prices cripplingly high and transportation costs of exporting goods for both road and sea freight at levels never seen before. The war in Ukraine and sanctions on Russia still cause uncertainty around rising fuel prices, and interruptions in the supply of machinery parts and raw materials continue to cause problems.

With interest rates rising to a base rate of 2.25% recently, there is added pressure on businesses exposed to debt burdens and rising mortgage costs.

Our Commercial Director Robin Eley shares his thoughts six months after his first interview to discuss why choosing British sheet metal suppliers can help alleviate supply chain and export concerns.

“Without doubt, UK manufacturing is feeling the same pressures of the global energy price hikes that are being felt through the entire supply chain, but keeping manufacturing in Britain has several benefits.

“The most significant is transportation. High shipping and logistic prices, along with delivery delays, have resulted in many supply chain issues.

“Many years ago, sourcing production outside of the UK was a viable way to sub-contract sheet metal fabrication, but as time has moved on, the cost-benefit, logistics and infrastructure that supported this kind of trade has now disappeared. British manufacturing has an annual output of £183 billion, and remains the ninth largest manufacturing nation in the world, providing 2.5m jobs across the country. By reshoring to the UK, companies benefit from a more localised control of production, ensuring that everything from communication to quality standards is to the highest standard possible.

“With world-class engineering here in the UK, and strong partnerships with leading suppliers, we have the capacity and ability to prototype and progress production opportunities without the high costs associated with logistics.

“As a company, we are taking further measures to be self-sufficient. We recently completed the installation of 1770 solar panels covering 3,570.5m² of roof space on the Alpha Manufacturing facility roof. These solar panels will allow the business to generate enough power to run our machinery. Over a 12-month period, the business will save 150 tCO₂ carbon emissions, the equivalent of a two-litre diesel car travelling one million miles, and taking us a step closer to achieving our carbon neutral commitment by 2037.

“We are increasingly supporting our customers, from a wide variety of sectors, to take on their production and alleviate some of the pressures facing UK businesses today.”

To find out more about how we can support reshoring your sheet metal production to the UK with our complete in-house fabrication service, get in touch.

A Day in The Life of A TIG Welder by Sean Atkinson

TIG Welder Sean Atkinson originally joined Alpha Manufacturing on a temporary contract but after showcasing his excellent skills and abilities, Sean quickly secured a permanent position and has been a valued member of the team for over a year.

Sean originally began his career as a plumber, but when looking for a change in career path, he decided to pursue his passion for TIG Welding, having previously achieved welding qualifications at college.

Sean tells us about what it’s like to be a TIG Welder at Alpha: “I work in the stainless steel department here at Alpha, mainly welding specialised parts for the food manufacturing industry.

“My day usually starts with my pre-checks, inspecting my welding set-up and ensuring that my materials and tools are in good working order. After this, I check the job list, looking specifically at the dates and priorities of each, in order to organise my work for the day.

“Before I start a job, I will need to thoroughly check the engineering drawings for the specifications. This can sometimes lead me to working closely with team members from other departments such as CNC folding or laser, to liaise on the fabrication of parts.

“I TIG weld a variety of parts throughout my day, sometimes using specialist techniques such as more complex purging to provide the upmost quality and uphold customer specifications. I then work with our linishing team on parts that need their services, and then quality inspect each part before it is delivered to our customers.

“What I really like about my job is the variety of work that I do, each part can be different which means I am constantly evolving my skills and learning. I am especially excited about the next phase of my role that comes with the opening of the new Alpha Manufacturing Chemical Technologies facility. Here, there will be specialised welding of exotic metals and my role will see me helping to co-ordinate and set up operating processes for the new factory.

“It feels fantastic to have been given the opportunity to be a part of this exciting development for Alpha, and that our TIG welding team will be growing with a new team based at the Chemical Technologies site next year. I look forward to my future here at Alpha, I hope to keep progressing my skills and knowledge and to eventually manage a team.”

Alpha Manufacturing Named Manufacturer Of The Year 2021 At Business Awards

Production Engineer Gemma Smith also awarded Young Employee of the Year

Staffordshire sheet metal manufacturing company Alpha Manufacturing is celebrating its achievements after being named ‘Manufacturer of the Year 2021’ at the East Staffordshire and South Derbyshire Business Awards. Commended at an awards ceremony held on 11^th November at the Pirelli Stadium in Burton, the fabrication company was recognised for its innovation during the pandemic, where the business quickly geared up its operations to support production of Covid-19 safety products, including hand sanitiser stations and protection screens used in NHS testing centres across the UK.

Alpha Manufacturing Production Engineer and former Higher Apprentice, Gemma Smith was also recognised at the awards evening, taking home the prestigious Young Employee of the Year award. The judges commended Gemma for her many achievements which include inspiring the next generation of engineers, raising awareness of women in engineering and apprenticeship routes, as well as her charity work which includes climbing Mount Kilimanjaro to raise money for an African children’s charity and taking on a Unicycle challenge to raise funds for Alpha Manufacturing’s charity partner and local hospice Katherine House, all whilst completing her degree.

Not only did the company take away these two awards, but it was also recognised as Highly Commended in the Best Use of Innovation or Technology category for its work towards Industry 4.0 Smart Factory goals, including implementing new technology and machinery such as the STOPA storage system which is the longest in the UK.

Talking about the win, Alpha Manufacturing Managing Director Paul Clews, said: “This award is a testament to the hard work and dedication of our team. It’s the people that make a business and without them, we wouldn’t be winning this award.

“During the pandemic, we kept production moving on essential items and within three months had the whole workforce back working within regulations, namely on Covid-19 safety products. To think that the products made here in our Hixon facility have helped to keep the UK safe as the country opened up again, and to continue to see these products helping to keep the country moving, makes me incredibly proud.

“A massive well done to Gemma too, who was our first ever Higher Apprentice here at Alpha, and who has continually pushed herself to be an exceptional role model to other young engineers. She always goes above and beyond in her role and is a real asset to our team.”

On winning the Young Employee of the Year award, Gemma Smith said: “I was totally speechless when they announced my name – I just couldn’t believe it. All of the other finalists were so worthy of winning, and so I was glad that I was able to share the stage with them.

“I just hope with this award I can show other young people, especially young women, what can be achieved through apprenticeship routes and to inspire people to go into engineering. I’m so lucky to have had the support of Alpha Manufacturing who not only funded my education but helped me every step of the way.”

Alpha Manufacturing Shortlisted in Three Business Awards

Shortlisted as a finalist in both the Manufacturer of the Year and Innovation & Technology category, with an employee also shortlisted as a finalist for the Young Employee of the Year Award.

Staffordshire sheet metal manufacturing company, Alpha Manufacturing has been announced as a finalist in three award categories at the prestigious East Staffordshire and South Derbyshire Business Awards.

The company is proud to have been selected as a finalist for the Manufacturer of the Year and Innovation & Technology Awards, with Production Engineer Gemma Smith also shortlisted as a finalist for the Young Employee of the Year Award.

The award comes at an exciting time for the business, which has seen significant growth in the last 18 months despite the challenges brought about by the pandemic. Since the start of this year, Alpha Manufacturing has seen a surge in demand for quality UK sheet metal manufacturing, resulting in the opening of two new divisions; Alpha Integrated Technologies and the most recent being Alpha Manufacturing Chemical Technologies, a 35,000sq ft purpose-built manufacturing facility in Beacon Park, Stafford in partnership with global chemical company INEOS Electrochemical Solutions.

The growing company’s production facility is the most technologically advanced in the UK. The recent extension of its STOPA storage system makes it the longest installation of its type in the UK and allows it to offer an unrivalled level of service in terms of efficiency and value. Commenting on the news, Alpha Manufacturing Managing Director, Paul Clews said: “What fantastic news! Being selected as finalists for these awards alongside other fantastic local businesses is a credit to the hard work and dedication of the Alpha Team who have worked tirelessly throughout the last 18 months to not only keep the business running through the pandemic and supply essential COVID safety products to customers across the UK, but to open two new sites since the start of the year, in response to unprecedented demand for our services.

“Our long-standing Apprenticeship Programme continues to produce some incredible young engineers and will continue to drive our business into the future. Gemma is the perfect example of a talented, dedicated and exceptional young individual whose commitment to everything she does makes us proud to have her as a part of our team.”

Production Engineer and former Higher Apprentice Gemma has been selected as a finalist for the Young Employee of the Year Award due to her achievements in her career so far, her commitment to raising awareness of STEM pathways for young women and her charity work. Gemma said: “I’m so happy that Alpha Manufacturing has put me forward for this award – it feels like a dream! Since completing my degree at Derby University through my Higher Apprenticeship at Alpha Manufacturing, I have worked hard to progress my skills and knowledge while also aiming to be a role model to other young women who want to pursue an engineering career. It just shows where hard work can take you!”

As well as being recognised for her performance and skills in her role at Alpha, Gemma has also raised money for local hospice Katherine House through a Unicycle Challenge and even climbed Mount Kilimanjaro for an African Children’s Charity while completing her degree.

The winner for each award will be announced at an Awards Evening at the Pirelli Stadium in Burton-on-Trent, home of Burton Albion FC, on Thursday 11th November.

Alpha Manufacturing on Track to Exceed Ambitious Environmental Targets

Being the most environmentally efficient business in the sheet metal manufacturing industry is at the core of Alpha Manufacturing’s strategy, leading the industry towards greener and more sustainable practices. Sharing a 35-acre site with sister company Bri-Stor Systems and Atlas Coating and work beginning on the new, 65,000 sq. ft state-of-the-art Alpha Manufacturing Chemical Technologies site in Stafford, Alpha is already exceeding its 5-year targets to reduce energy consumption, waste to landfill and increase recyclable waste.

We spoke with Bri-Stor Group Health, Safety and Environmental Manager Darren Bates, to find out more about how the business has achieved this success.

Tell us more about environmental strategy and why it’s so important.

“The 14001 epitomises how important having a stringent environmental policy in place is to businesses. We know our targets are ambitious, but achievable, and we’re a company ready to make a mark in the manufacturing industry for our sustainability goals.

“Our 5-year environmental strategy consists of three key areas: Reduction of electricity and energy consumption, reduction of general waste produced and therefore waste to landfill, and increase our recycling waste rate. One year in to this plan, we are exceeding our goals through innovative and proactive approaches.

The strategy will allow us to futureproof our business and be the catalyst of change in our industry.”

How have you managed to reduce energy consumption across Alpha?

“As a large site, with 24/7 manufacturing capability, reducing energy consumption has always been a top priority for our company. Recently, our factory underwent a large project to make a big dent in our average energy consumption, futureproof our business and reach our 5-year targets. By strategically converting all lighting on premises to CEMA LED Lighting, we have reduced our kWh production by nearly half a million. The kWh of energy saved is equivalent to 36,344,455 smartphones charged! This has resulted in us already beating our yearly kWh electricity target by over 13%, which is an annual CO2 saving of 107.76 tonnes, equivalent to 270,822 miles driven by an average passenger vehicle.

“This is not the only energy saving innovation we have planned either. A project is under way to have switched completely to solar power in the next four years. The installation of solar will see our 3,570.5 square meters of our facility installed with 1960 roof-mounted solar panels. This will produce a kWh energy saving of around 733,043 per year, with the eventual aim to be entirely self-sufficient in our energy usage within six years.”

Across the Bri-Stor Group, we were previously producing 200 tonnes of waste per year, how has the plan allowed us to reduce the amount of tonnage wasted and by how much has it reduced this by?

“Having switched to three bailers and one mini-compactor to decrease the amount of waste that goes to landfill, we have now reduced our carbon footprint by 75%.

“As a business, we are now classed as a ‘zero to landfill’ company, working with leading waste management company Veolia, who themselves stopped using landfill around 18months ago, as our waste is now processed into Reuse Derived Fuel (RDF). The RDF process replaces fossil fuels such as coal, gas and oil. Filtration is used to produce as much lower CO2 than regular methods, meaning it is cleaner and less harmful to the environment.”

How significant is recycling to Alpha and how have we increased the amount of waste material we recycle?

“Intrinsically linked with the goal of reducing general waste is the increase in recyclable waste. With an excess in quality materials, making sure these are recycled and not wasted, is key to our strategy.

“The bailers are used to mass recycle our waste materials such as all cardboard and plastic. The implementation of this equipment, along with building a workplace culture around reusing and recycling, has meant that we are on track to beat our ambitious target of 55 tonnes of recycling by the end of 2021.”

In summary, what is the future of the environmental strategy for Alpha?

“These initiatives across the three strategic areas, have meant that in 2021, we are already not only on track to meet our environmental targets but in some areas beating these already, and our hope is that we will have exceeded our ambitious targets by the end of the year. This will also have a big impact on the entire 5-year plan, which we hope will mean we can keep excelling in implementing our environmental strategy and innovations, to be one of the most ‘green manufacturers’ in the industry.”

ISO 45001: Why our take on occupational health sets us apart

Recently, the International Organisation for Standardisation released ISO 45001 – the world’s first International Standard for occupational health and safety (OH&S). This new health and safety initiative enables organisations to proactively improve its occupational health and safety performance.

The ISO 45001 replaces previous frameworks such as OHSAS 18001, and was developed with the input of experts from more than 70 countries. Due to the nature of the ISO 45001 being the first of its kind in OH&S, many organisations are still working to previous and sometimes out-dated frameworks.

As a business that values the importance of keeping our workforce safe and happy, all businesses within the Bri-Stor Group moved immediately to implement the new framework, in order to create effective policies and objectives to keep quality high and risks low.

Darren Bates, Bri-Stor Group Health, Safety and Environmental Manager, explains why being an early adopter of the ISO 45001 benefits our business, and therefore our customers: “The Bri-Stor Group employs over 500 people across our four companies Bri-Stor Systems, Alpha Manufacturing, Atlas Coating and Hex Signs and Graphics. Our large workforce alongside as well as the risks involved in the manufacturing industry, means that having a robust framework in place to ensure occupational health and safety is a top priority for the Group.

Many companies have relied upon earlier frameworks, but here at the Bri-Stor group, we understand that with a changing workforce and business booming more than ever, risks are ever-present. It’s only by identifying these possible risks early that we can avoid possible issues that could affect our workforce and out output.

At its most basic level, the benefits of this new framework to businesses are related to productivity. This productivity comes from reduced absenteeism and staff turnover, an increase in staff moral and a culture built around an informed workforce with individual autonomy for their own workplace health and safety.

Having experienced success in implementing new health and safety reporting systems and building awareness of risks in our business to new starters, we embraced this new International Standard and strove to gain certification as soon as possible.

We are proud to have gained the ISO 45001 certificate, as our early adoption of the framework exemplifies our commitment to keeping our workforce safe and happy, and therefore our output and productivity remain high.”

Jonathan Holyhead Celebrates 30 Year Career with Bri-Stor Group

Jonathan Holyhead, Bri-Stor Group Finance Director, celebrates thirty years with the business this month (July 2021) and has been an instrumental part in the company’s significant growth and achievements during that time. Joining the business in his late teens, Jonathan has accomplished many great things in his career so far, and is excited for the next chapter in Bri-Stor Group’s expansion plans.

Commenting on Jonathan’s contribution to the business, Bri-Stor Group CEO Martin Smith, says: “Jonathan is the very essence of this business and is a loyal, trusted advisor to the Bri-Stor Group. In the time that Jonathan has been in the Group we have grown significantly and added new divisions to the business, new premises and grown our workforce ten-fold. Combined, all of these things have presented opportunity and risk and with Jonathan’s fierce control of our financial status, we have been able to deliver controlled and measured growth.

“I am personally, delighted to congratulate Jonathan on this significant achievement. His support and commitment during the pandemic has been unwavering and there’s no doubt, with Jonathan’s skills we remain strong and in a position to continue investing in the Group’s continued success.”

In response, Jonathan adds these words: “As Martin explains, the business has delivered incredible growth in the last thirty years and I am delighted to be part of the success story. Working alongside the senior leadership team has been rewarding in itself and there’s no question, my own professional development has been down to the company’s investment in me. As we look towards even greater growth and prosperity, I am excited for the next chapter of my career and achieving the next milestone.”

Why being an apprentice has changed my career aspirations

Making the decision to apply for an apprenticeship with Alpha, has to be the best career move I could have possibly made.

Going into the Apprenticeship Scheme with just the basic idea that would be able to gain experience alongside gaining qualifications sounded like an ideal choice. But little did I know there is SO much more to it than simply learning on the job, there’s a whole new world with a thousand levels to unlock and I’ve only just opened the first door.

Let me take you back to the start of my journey. I had never been in an engineering environment before, I was unsure if I would fit in or if I would be good at it but I’ve had many mentors along the way who have guided me and made me realise that it doesn’t matter if you don’t know how to do something as long as you put enough effort in to learn, there are no limits to what you can achieve. I always wanted to be at the top of everything I took part in, but the path wasn’t always clear on how to get there and I always questioned if I could make it to where I want to be, but now as I’m learning and becoming more confident in my abilities through guidance from my peers at Alpha Manufacturing, I can see that it’s actually possible to make it to the top and I now have much bigger career aspirations – I’m certain I can achieve them.

I’ve witnessed first hand the greater opportunities that Alpha give to those who are willing to put in the effort. I’ve been given the opportunity to progress into the commercial world whilst applying the technical knowledge I have gathered from my initial two years of experience at college and working as part of a team on the shop floor. Each and every one of us is more than capable, but sometimes the challenge is finding a way to unlock that potential. Being fortunate enough to work with a close knitted team at Alpha, I can express my feelings freely and I’m not afraid to ask questions or say the wrong thing as I know that I won’t be knocked down, I will be educated and pushed into the right direction so that I can continue to learn and bank more knowledge.

Ultimately, Alpha Manufacturing does Apprenticeships, and they do them incredibly well. For the past three years I’ve seen each new wave of Apprentices arrive, settle in and set off on their own personal career path. Now, Alpha has launched a Higher Apprenticeship Scheme for those who are already able to take the next step and I’m very excited to meet and work alongside the future engineers of Alpha Manufacturing.

Dare to be great?

How It’s Made – Tread Plate Rear Step

The Customer

Alpha Manufacturing sister company Bri-Stor Systems are a leading commercial vehicle converter, supplying leading UK brands with their fleet vehicles. This product is fitted to many of the LCV’s that Bri-Stor produce.

The Product

An LCV rear step with tread plate pattern for extra grip. This part is profiled, punched, welded and powder coated. Alpha produce many variations of these type of steps in high volumes, both for Bri-Stor and other customers.

The Challenge

Previously, the profile and pattern of the tread plate step were produced by two separate processes, firstly by using a CNC Punch machine to create the tread plate pattern and then secondly by Laser Cutting the outside profile.

This sometimes resulted in misalignment issues between the two processes where the laser cut profile didn’t match perfectly with the tread patterned area. This meant that the misaligned part would need to be rejected and scrapped, with the part then reproduced using the same two processes. The issues with this are primarily high material waste and low efficiency due to the re-processing of parts.

The Solution

By investing in a Trump TruMatic 6000 laser/ punch combination machine, Alpha were able to combine the two processes into one. The tread pattern and outside profile can be created simultaneously, dramatically reducing the overall processing time.

The Benefits

Combining these two processes using the Laser/ Punch combination machine brings many benefits to both Alpha and their customer. By removing one process completely, overall production time is significantly reduced, increasing efficiency and ultimately making the part more cost effective.

Accuracy is also improved markedly as the machine is able to auto align the laser profiling to the punched pattern as it processes, eliminating risk of reject parts and waste material. From Alpha’s perspective, this means a much more efficient and effective manufacturing process which frees up resource elsewhere and minimises the risk of re-processing parts. The overall benefit to the customer is more reliable manufacturing with no quality concerns as well as a potentially more cost-effective part.

Value Analysis/ Value Engineering in Sheet Metal Fabrication

What is Value Analysis/ Value Engineering?

Value analysis/ value engineering (V.A.V.E) is a process of reducing cost / increasing value for the customer in the production of components and assemblies. This is an extremely important exercise for OEM’s when working with a manufacturing partner as products are often produced in high volumes. Any small saving which can be made in the manufacturing stages can equate to huge overall savings across a product lifecycle.

V.A.V.E is often combined with other manufacturing principles such as D.F.M.A (Design for manufacture and assembly) in order to optimize the product in the design phase ahead of production. A manufacturing partner may suggest alternative solutions to achieve the customer requirements. For example, a new tool may be designed to create certain forms when used with a punch or press brake. This may equate to a small upfront cost for the customer but result in a much bigger saving in the long term through reduced processing or increased efficiency.

When does Value Analysis/ Value Engineering occur?

A manufacturing partner can either be asked by a customer to manufacture a product to an exact specification (Design to print) or to take a more involved, collaborative role in the design phase (Design and specification manufacture).

In the case of design to print projects, there may be an opportunity for the manufacturing partner to review the existing design, using DFMA principles to suggest modifications with the aim of reducing cost. This may include changes to process, for example, CNC punching forms / extrusions as opposed to welding separate parts together, removing processing time, reducing material and ultimately lowering the cost for the customer. Product function and features are also reviewed during this phase, with alternative solutions and possible design changes suggested. These alternative solutions are then tested and costed to assess feasibility. Following this process, the manufacturing partner will propose any design or process changes to the customer, along with a cost analysis.

Where customers require design input from the manufacturing partner, NPI (New Product Introduction) teams will be heavily involved in the V.A.V.E process from the outset. This allows the product to be fully optimised for manufacture with all aspects considered well ahead of production. Materials, features, processes and resourcing can all be considered fully, with a comprehensive cost analysis. Working in this way is the most efficient and cost-effective solution for the customer as design for manufacture insight informs production from the outset. By taking this time early on in a project, the customer is assured that the product is fully optimised for manufacture and as cost effective as possible.

V.A.V.E in Practice

A good example of Value engineering in practice is the electrical enclosure box featured in Alpha’s V.A.V.E video. Working closely with the customer (a global electrical systems manufacturer) from the outset, Alpha were able to make various design suggestions which both improved the products’ functionality and reduced the overall cost to the customer.

By implementing DFMA principles to the design, Alpha reduced the amount of processing required during manufacture and in some cases, completely removed a process all together. Spacers on the rear of the box which allow it to be screwed to a wall securely, leaving space between the box itself and the surface. The had previously been made by welding a washer to the box after manufacture. Alpha instead achieved this by incorporating it into the CNC Punch process. A small tooling investment allowed for the form to be achieved without any welding.

A design change was also suggested to reduce the number of these spacers from four to three without affecting the stability of the box once fixed to a wall. By removing the welding process completely, reducing material by negating the washers and reducing the number of spacers, Alpha achieved considerable savings for the customer whilst also improving the design and functionality of the product. The small savings made on each product, when calculated over the high volumes produced, equate to a significant saving for the customer.

In addition to reducing manufacturing cost, Alpha also made several suggestions to improve the product and reduce manual processing on site by installers. Several conduits knock-out features were added to the sides of the box, using a CNC punch tool. The installer on-site is then able to knock-out the appropriate sections and feed through any cables. This removes the need for on-site drilling of the box, saving time and also improving the aesthetics of the finished product.

Another CNC Punch process was incorporated to stamp electrical earthing symbols onto the inside of the box, instructing the installer where to place certain elements of the internal system. Previously, stickers had been placed here which again, was an additional process and cost for the customer. They could also easily be removed or fall off, whereas the new punch process created an indelible stamp.

Can V.A.V.E Save You Money?

Alpha’s experienced NPI and engineering teams have a wealth of knowledge in precision sheet metal fabrication and work with each customer to value engineer their products where required. Often, there are manufacturing considerations that the customer is not been aware of or alternative processes that can be utilised. If you have a product you’d like to discuss, get in touch with our sales engineers who are always happy to discuss product design and offer V.A.V.E advice.

Alpha Manufacturing Announce Latest £1 Million Machinery Investment

Alpha Manufacturing have an announced the latest in a series of manufacturing machinery investments, which will see a brand new £1 million Salvagnini P4 Lean panel folder added to their existing CNC folding department.

This latest investment is a continuation of Alpha’s long-term investment strategy which has seen installations of a STOPA storage system, TruPunch 5000 S12, TruLaser 3030 and Trubend 7000 machine take place over the past 18 months. It also comes shortly after work began to build a brand-new office and canteen facility on their 35-acre Hixon site.

Why Invest in a New Panel Folder?

The P4 Lean will replace the outgoing Amada TBZ panel folding machine which has been in operation for 15 years and will hugely increase Alpha’s sheet metal folding capabilities. A host of additional features and systems have been specified with the P4 to maximise productivity and efficiency, including Salvagnini’s latest interactive programming suite – Streambend, which allows programmers to run a virtual simulation of the part in a 3D environment before any material is processed. Alpha will be one of the first sheet metal fabricators in UK to use this software.

Streambend offline programming software, combined with the P4’s ability to integrate with Solidworks CAD software will dramatically increase Alpha’s panel folding capacity. By moving away from manual shop floor programming to offline office-based programming, Alpha will now be able to offer a much more efficient panel folding service.

Key Features of the P4 Lean:

ABA blankholder

The ABA blankholder automatically changes its configuration and its length according to the dimensions of the panel to bend without any input from an operator.

CLA tool

The CLA tool allows the P4 to make multiple positive and negative short bends to the same part, engaging and disengaging quickly and automatically between the blank and bending blades. This function is ideal for creating upward and downward tabs.

P-tool

The P tool allows for the handling of very narrow profiles and creating tubular, hidden or radiused bends. It also allows for preformed parts to be folded easily and automatically.

MAC 2.0

MAC 2.0 (Material Attitude Correction) detects any material variations by the panel bender and, if values are outside the tolerance range, automatically compensates by adjusting the blade movements.

Automated load/ unload

An automated loading/ unloading carriage positions the raw sheet in the machine whilst simultaneously pushing finished parts towards the unload conveyor.

Thanks to Salvanini’s clever automated tools, the p4 is able to fold much more intricate and complex parts, where limitations to the TBZ had previously seen these types of components folded manually on press brake machines. Complex parts with details such multiple positive and negative bends, tabs or embossing have until now been manually re-positioned by an operator for each bend. The P4 however, enables all of these to be achieved in one seamless process, dramatically reducing processing time and manual handling.

Long Term Plan

As with all of Alpha’s recent investments, the P4 forms part of a long-term factory development plan which will eventually see it integrated into the STOPA storage machine. This will further automate panel folding capabilities as raw material is fed into the P4 and removed once processed without any manual handling.

“The TBZ machine had served us well but the time came to replace it and as with all of our recent investments, we looked at the bigger picture when choosing a new machine. We don’t just want a like like-for-like replacement but an upgrade which opens up new capacity and opportunities for us whilst also fitting into our overall long-term plan for the business. The P4 ticked a lot of boxes for us in terms of its capabilities and what this allows us to offer our customers.”

Paul Clews – Alpha Manufacturing Operations Director

Installation of the Salvagnini P4 is scheduled for early 2019 and will take around 6 weeks to complete. In the meantime, Alpha’s panel bend operatives and programmers will undertake intensive training on the new machine. Programs will be created well in advance of the machine installation so that production on the P4 can begin immediately.

Alpha Apprentices Complete Intensive Team Building Week

The annual trip to Elan Valley has become an integral part of Alpha’s Apprenticeship programme with all 1^st year Apprentices attending ahead of their workplace training.

The three day course began with basics of team work and communication and gradually allowed the Apprentices to develop in their teams , solving increasingly challenging tasks.

An early start saw the team leave the Bri-Stor Head Offices at around 6.00am, arriving in Wales just before 10.00am where they were welcomed by course leaders and given their brief for the day.

The day consisted of a series of communication focussed tasks designed to focus the group on the strengths of individual members and importance to the team as a whole.

The first challenge of the day was a test of team communication where a ball needed to be passed between members in the quickest possible time. From a slow initial attempt, the team were asked to focus on every individual’s role within the team and how better communication could improve performance.

A range of team challenges followed, from building the tallest tower out of bamboo poles, to creating a perfect square and various orienteering tasks, all carefully constructed to test the communication and team working of the teams. After each challenge the Apprentices where given time to reflect on how better communication and joined up thinking allowed them to progressively improve their performance.

The day concluded with an in-depth review of the days activities and course leaders delivered some classroom theory to back up the practical work that the teams had throughout the day.

The second day tested the teams further, building on the previous day’s progress and pushing them to achieve much more difficult goals by working together in an organised and thoughtful way.

A high rope challenge required individual team members to navigate a tree top course while receiving instruction from others on the ground. Communication was vital in passing on collective team knowledge on the best way to tackle tricky obstacles.

The challenge finished with a leap of faith where team members on the ground provided advice and encouragement to their partners for them to leap from a high platform.

Next up was a raft race across the Elan Valley Damn on rafts built by the teams. Using collective thinking and solid communication, the teams worked out a sound raft design and method of travelling in the water. A short de brief followed where the teams reflected on their successes and areas of improvement.

Again, the day concluded with an evening of theory delivered by course leaders where the Apprentices learned the importance of individual team roles, delegation and responsibility. They were asked to apply this to the days activities and reflect on how they might have streamlined processes.

The third and final day focused on planning and executing a solution to a specific problem. Teams were given a set of instruction on how to complete a task before being allowed time to discuss and agree an approach to best solve the problem. After the first challenge of the day the teams reviewed their individual strategies and discussed where they could have made improvements.

Course leaders then gave the teams 9 individual challenges to complete by the end of the day and allowed them 3 hours to put together an effective plan to complete each. The teams then set about completing the hill walk, a nail puzzle, flag/logo quiz, tower build, forest orienteering, team juggle, maze ball, mountain bike trail and archery challenges, following their agreed plans.

One final evening session saw the Apprentices review the entire course and the skills they had learned throughout, specifically communication, planning and leadership, efficiency and effective planning. The course concluded with the Apprentices being asked to consider how all of these elements contribute to their success in the working environment.