People and processes: tools of the trade

The Machinery & Manufacturing team recently visited MAPAL’s state-of-the-art production facility in Rugby, keen to meet the staff who turn advanced tooling concepts into reality

This year sees global tooling manufacturer MAPAL celebrate its 75^th anniversary. As a true technology partner to its customers, MAPAL has built its enduring success on the development of efficient and resource-saving manufacturing processes.

“The global manufacturing strategy sees commonality and compatibility across all facilities,” said Eugene Nugent, National Sales Manager at MAPAL UK. “In line with the Headquarters in Germany, Rugby has the same machines and manufacturing processes, which enables us to produce a large percentage of the MAPAL portfolio domestically. We’re very self-sufficient and have a full project team able to handle everything from a single tool to a whole programme of tools based on cost-per-piece tool management.”

Electric performance

Major tooling projects from concept to in-house manufacture are a core competency at MAPAL UK, with Technical Manager John serving as the point of contact for customers. A company veteran of 39 years, John’s recent tasks included the successful development of a special PCD tool for a large EV motor housing. The company responsible for machining the castings was finding it difficult to produce the large bore diameters and chamfers with an unsupported tool due to chatter.

“I developed a special PCD tool that delivers the required levels of stability to meet the surface finish and bore-to-bore alignment accuracy demands,” said John. Designed and manufactured in Rugby, this modular, adjustable tool is now in use at the customer’s site.

Another conduit between MAPAL UK and its clients is Project Engineer Luke. A company stalwart with 34 years of service, Luke spent 10 years in the workshop and 22 years in sales and service, building invaluable knowledge of the business and the industry.

“My current role centres on project engineering,” he said. “We have a major project at the moment involving the development of around 120 tools for three complex transmission housings. We’re now at commissioning stage, machining the first parts and making final adjustments. It’s a solutions-based role and I really enjoy it.”

Grand designs

Design Engineer Kym, himself able to call upon 27 years of MAPAL experience, provides key support for new tool development by taking the engineering reports, sketches and component drawings gathered by the sales engineers at enquiry stage to generate a detailed drawing of tools using PTC Creo 3D parametric CAD software.

“Every job is different, which is what makes it interesting,” he stated. Like many at MAPAL UK, Kym started his career on the shop floor before joining the design team in 2008. This progression is indicative of the career opportunities that MAPAL UK provides.

A further great example is Abi, who started at MAPAL in 2004 as an admin assistant. Today she is Head of Customer Service, orchestrating core business functions that include order processing, technical quotations, purchasing and project management through the various stages of design and production.

“I cover all bases and try to support everyone,” she said. “We use SAP software to help manage projects through their lifecycle and take advantage of Microsoft SharePoint documents to ensure everyone knows what they need to do, by when.”

While the prevalence of long-serving employees at MAPAL UK tells its own story, the company also believes in the introduction of new talent; fresh eyes that can sometimes see things through a slightly different lens. A case in point is Carl, who joined MAPAL UK as Manufacturing Manager one year ago to oversee a production team of 21. With a background in automotive, Carl’s experience has already provided his new employer with additional gains in a number of key metrics.

A sight to behold

Stepping on to the shop floor at Rugby, the high level of technology and process optimisation is immediately apparent. Take the example of a hard-worked PCD cutter arriving at MAPAL for refurbishment. The first stop is tool assessment, the report from which determines the process route through the shop, typically beginning with a visit to the brazing section for removal of worn PCD inserts and the fitting of replacements.

Tool cleaning is followed by wire erosion using state-of-the-art EDM machines dedicated to producing forms in the inserts of PCD cutters. MAPAL can load the machine carousel with HSK63 back-ends of similar tools and run unmanned overnight and at weekends.

Further EDMs on site see use for wire eroding diamond. From here, some repaired tools go straight to inspection, while others require grinding using specialist machines for PCD applications. Laser marking and final inspection follow with the assistance of a Zoller SmartCheck, a powerful measuring machine dedicated to cutting tools.

On solid ground

Advanced five-axis grinding machines form part of the solid-carbide tool reconditioning section at MAPAL. Currently working here is Third-Year Apprentice Ethan and his mentor, Manufacturing Engineer Luke. At time of visit, the pair were busy running a new program for re-grinding the gashes, facets and chamfers of a worn solid-carbide cutter.

Ethan is among numerous apprentices on the shop floor. Fourth-Year Apprentice Oscar, for example, has just completed an NVQ in grinding, while Second-Year Apprentice James can currently be found operating the facility’s grinding machines. Third-Year Apprentice Conor, whose hobby is building model steam engines, has worked in the wire EDM, grinding and milling sections. The milling and turning sections are where new tools begin their manufacturing journey at MAPAL UK.

“Our youngsters are amazing,” stated Carl. “I sometimes forget how young they are because they all seem so mature. They seem to excel at everything and it feels like the company’s future is in great hands.”

The industrial world is changing, but so is MAPAL, a company that’s in tune with the customer requirements of today and tomorrow. Moving forward, the business wants to maintain its state-of-the-art, best-practice manufacturing ethos with a focus on continuous improvement. Moreover, MAPAL is determined to uphold its reputation as a company where people enjoy being part of a team that delivers positive outcomes for customers.