Manufacturing in Medway and Mid Kent

Diploma Support programme

Mk3

Contents 2 Morgan Timber

4 Hobarts Lasers

6 LB Signs

7 Medway Galvanising

8 MC Model Making

10 D.A. Printers Ltd.

12 Talon

13 Emmerich Berlson

14 Cook

16 Maltbury Staging

17 ACS Lasers

18 Delphi Injection

20 BAE Systems

22 Aylesford Newsprint

IntroductionIndustry and Education have been working together to deliver applied learning experiences for students in the 14-19 sector for many years. The most recent National collaboration is the new Diploma qualification at levels 1,2 & 3, where classroom studies are supported by industrial practice and project work alongside continual assessment and examination.

Awareness of the breadth of opportunity in Manufacture is the focus for this publication, with a range of examples from industry in the region keen to share their systems and processes with students. The visual evidence in the diversity and complexity of these wealth creating sectors is a key element in attracting students to embark upon courses of study in preparation for the ‘world of work’.

Aimed at all those involved in delivering the Diploma in Manufacturing and Product Design, this publication is a stimulus for the way we collectively educate the professional, technical and creative element in our society. Bringing learning to life through applied educational experiences firmly rooted in industrial scenes is part and parcel of the Diploma delivery. M3k has developed to explore the work-education experience, develop further links between Education, Industry and local EBP, and facilitate the development of applied learning skills in our students. To meet the needs of the changing educational and commercial worlds we look to develop further collaborative projects which will align our thinking and streamline our delivery. Our current mandate has highlighted potential ‘synergy’ activities in this region: web based and e-teaching resources may well prove to be the vehicle for expressing future development. Supported by the University of Greenwich, Chatham Maritime, we look forward to seeing you in 2010 as part of the M3k group of activities.

I would like to thank all the contributors who have enabled this publication to be developed and welcome any correspondence or ‘joined up thinking’ which it catalyses.

Neville CrouchDiploma Development Manager: Manufacturing and Product Design - Medway Council.

Director of Technology: Sir Joseph Williamson’s Mathematical School, Rochester. t- 01634 844008 e- crouchn@sirjosephwilliamson.medway.sch.uk

Morgan Timber has been selling top quality timber in the Medway area since 1910. The company has very large stocks of hardwood and softwood as well as modern storage and handling facilities and an extensive machine shop. This enables Morgan Timber to offer a comprehensive, reliable and flexible service to a wide range of customers.

One of the company’s specialities is the production of bespoke mouldings of virtually any profile to precisely match a drawing or pattern. Profile cutters are made in their state of the art toolroom, which reduces lead time to a minimum and keeps the company in full control of the quality and accuracy of the finished product.

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Morgan Timber

Finished timber profile ready for despatch.

New cutter profile is designed to match scanned image using a CAD package.

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Profile cutters in action inside moulding machine.

Template of new profile cut using CNC router. The profile cutters are produced by a grinding machine following the template.

Timber profile is produced in one pass of the moulding machine.

Hobarts is the market leader in manufacturing cast acrylic products and supplying laser cutting and engraving systems. Our newest operation is the supplying of laser compatible materials such as laserable laminate and acrylic.

Our business is very much focussed on supporting our customers who include schools, colleges, universities, banks, government agencies, international corporates and many more.

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Hobarts Lasers

Diamond polishing

5Packing shot - final encapsulated product

Encapsulation process - casting acrylic block.

Hand polishing

Laser engraving anodised aluminium.

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Weeding Vinyl using blade.

LB Signs

Using rubber roller to create banner hem.

LB Signs was formed in 2007 and specialises in providing vinyl and digitally printed signage to companies throughout the Medway Towns and South East London. The Chatham workshop provides:-• Fascias • Vehicle Livery • Window Graphics• Banners • Exhibition Graphics & Displays • Design

Using Eyelet Press to insert nickel eyelet.

Printing banner on to PVC banner fabric.Weeding Vinyl using blade.

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Medway Galvanising is expert in the provision of hot dip galvanising. The company operates to the latest galvanising standard BSENISO 1461.

Galvanising is the process of applying zinc to mild steel to provide it with a strong and protective coating that lasts for up to 100 years.

The end finish is resilient to aggressive handling, which over the last 150 years, has been solidly proven to provide a long lasting tough and low maintenance coating. Importantly, galvanised coatings are also recyclable, giving the steel an almost continuous life span.

Medway Galvanising

MC Modelmaking Ltd produce a broad range of models for use within the fields of architectural design, property development, museum and educational display, and themed attraction sculptural and set dressing props.

These photographs identify key processes involved in producing an architectural sales model for a new residential development.

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MC Model Making

Working from Autocad drawings, aerial photographs and sketches, the most suitable scale is discussed and agreed with the client, and the

overall scope and level of detail is then decided.

From CAD artwork, scale model elevations and components are cut from acrylic using a laser.

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The building core/mass is machined from resin-based model boardand elevations and roof details are applied.

Using printed scale drawings the model base is constructed to represent accurate level changes on the site, then detailed, spray-painted and landscape textures applied.

Each of the completed buildings are spray-painted and windows are applied. Finer detailed elements such as walls, landscaping, trees and street furniture are added once the individual buildings are fitted to the base.

Established in 1968, D.A. Printers Ltd supply many local and national customers with a wide variety of printed products, some of which are listed here.

• Continuous forms • Carbonless Sets, books or pads • Pre-printed laser sheets • Bespoke printed Stationery and Envelopes • Brochures / Reports / Price Lists • Invitations / Menus / Calendars • Leaflets • Posters

Continued investment means we now print using both litho and digital technology and use far less chemicals.

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D.A. Printers Ltd

‘Chemistry free’ computer to plate system.

In-house design.

Litho quality digital colour printing.

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Web printing at 35,000 forms per hour.

Precision punching equipment.

Talon Manufacturing Ltd produces millions of clips and fixings for the plumbing industry each year. Illustrated are various machines used in production. • Injection moulding • Automatic assembly • Automatic packing

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Talon

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The country’s leading manufacturer of workbenches for the education market based in Ashford, Kent, since 1966.

Emmerich Berlon

Automatic saws size each piece of timber

All workbenches are hand assembled and finished.

Powerful multi headed sanders ensure a perfectly smooth surface to worktops

Cook is a unique family business based in Sittingbourne, selling fantastic ready meals and puddings in our shops throughout the South East of England, our National On-line Delivery Service and through our wholesale business selling to farm shops and independent food producers.

Our founding principal when we started in 1997 was to cook using the same ingredients and techniques that you would use at home so everything looks and tastes homemade. Today we stick by that principle, we just use bigger pans and larger quantities than you would!

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Cook

Our chefs place the side of salmon onto trays so they can be blast frozen.

One of our finishing assistants loading our meals onto the sealing machine before sleeves and labels can be applied.

All of our portions are dished by hand!

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One of our chefs hand mashingpotatoes in a 400 litre bratt pan.

Temperature checks taking place on the side of salmon. It is vital that the food is chilled to the appropriate temperature before work commences and that it does not get too hot whilst ingredients are added to complete the meal.

High quality fresh ingredients are always used.

Maltbury is a staging manufacturing company. We supply modular and fixed staging for the entertainment industry, churches, schools and colleges.

All our products are manufactured ‘in-house’ from locally sourced materials wherever possible. We specialize in aluminium, steel and wooden staging systems.

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Maltbury Staging

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ACS ImagingACS Imaging was formed in October 2000 and has evolved as a company able to provide signage for clients large and small. They strive to provide a quality service bringing the corporate feel to all businesses, using up to date methods and materials, coupled with tried and tested experience to produce signs of stunning effect, from conception through to installation and ongoing maintenance.

The company uses materials from vinyl through all plastics, metals and timbers to produce: Illuminated Signage • Directional Signage • Sign Systems • DDA Signage • Vinyl Graphics • Stainless Steel Signs • Internal Signage •

The Technical Centre is the base for approximately 500 engineers and other staff and is primarily responsible for the design and development of High Pressure Diesel Common Rail Pumps. To support this activity the Technical Centre has a Prototype Manufacturing Department where low volume prototypes are produced. This can involve making 1 off components produced from bar stock to small pre production batches of up to 100 parts where components are produced from castings, forgings or part finished parts from serial suppliers.

Within the department, the quality of the component orpump is the primary focus, there is little point in producing parts that are out of specification. Therefore a rigorous quality approach is taken and the dedicated metrology room is in constant use.

Machine tools in the department vary from fully CNC controlled 7 axis machining centres to precision grinding machines which are manually controlled.

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Delphi Injection

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The BAE Systems site, alongside the airfield at MarconiWay, Rochester, is one of the largest local employers with a long history of the development and production of high technology components and products stretching back more than 60 years. During that time it has recruited apprentices, trainees and graduates consistentlyand since 1998 alone has recruited more than 120 apprentices into their advanced apprenticeship scheme to undertake business and engineering studies.

Nationally BAE Systems currently has nearly 1200 young people on various forms of apprenticeships. Here are some trainees and visitors with samples of BAE System’s products manufactured on the Rochester site .

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BAE Systems

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‘Paper Machine 14’ makes over 1km of paper a minute and is nearly 10m wide, producing about 900 tonnes of paper per day. The machine consists of rollers, presses, guiding fabrics to support the sheet, drying cylinders and other specialist paper machine equipment. We use nondestructive testing techniques such as on-line scanning, thermal imaging, vibration monitoring and laser alignmentto predict failures before they happen and force the machine to stop.

Through incineration of a waste product (sludge) we heat water, create steam and generate electricity, some of which we sell back to the National Grid.

Finally, we wrap our reels in a protective liner and place inner and outer headers to reduce damage to the reels in storage and handling. The whole line is fully automated and controlled by PLCs, hydraulics, pneumatics and robots.

Aylesford Newsprint

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Paper collected from re-cycling points all across the UK is stock piled.

Our combined heat and power plant.

A series of floatation cells heat the water and pulp stock and through a natural scientific process involving soap and air bubbles the ink rises to the top of the blend and floats off. This leaves a nice bright stock for the newsprint to be printed on.

The de-inking plant, part of the fibre preparation process.

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The ‘wrapline’.

‘Paper Machine 14’

Acknowledgements

M3k DirectorNeville Crouch

Designed and Printed by D.A. PRINTERS Ltd. 01634 684243 Photography by Alan Duncan 01303 243935email: sales@daprinters.co.uk www.photographerskent.com

Manufacturing in Medway and Mid Kent

Delivering the 14-19 education and skills programme

Line of learning networks are supported and funded by the Learning and Skills Improvement Service (LSIS) as part of the Diploma support programme. However, this document has been created by a network leader (an individual contracted by the Diploma support programme to lead a line of learning network) and there-fore the content does not necessarily reflect the opinions of LSIS.

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Thanks go to all those companies featured in this publication and our delivery partners.