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Transcript of Preci-Spark brochure
Business to Business conference
Matthew Jones Director-Business Development
andre russell Customer Liason Manager
friday 30th March 2012 British eMBassy,35 rue du fauBourg st honoré,75363Paris
World class engineering solutionsPreci-Spark is a leading European contract manufacturer for the high technology
industries delivering manufacturing solutions to the global market place.
Established in 1960 the company employs 450 people across 6 manufacturing
facilities in the United Kingdom.
As a process based manufacturing specialist, Preci-Spark delivers an array of
components, complex fabrications and assemblies to the Aerospace and Industrial
markets. Our extensive portfolio of in-house processing capabilities allows greater
production control, accelerated lead times and reduced costs.
exceeding customer expectations
Being customer focussed in all our activities,
Preci-Spark embraces the requirements defined in
AS9100 Revision C.
We are committed to maintaining a Quality
Management System of the highest possible
standard.
Our NADCAP approved processes include: vacuum
brazing, heat treatment, electro-discharge machining,
laser machining, welding and non-destructive testing.
cost efficient enabled by robust quality systems
HistoryRalph Jones, our Chairman, founded Preci-Spark in 1960.
The company was born into special process manufacture with the
purchase of 2 Wickman electro-discharge machines.
With the firm principle of investment in people and technology the
company has grown organically.
Over the decades, Preci-Spark has had ventures in other markets,
however its core business operations have always been high tech
manufacturing, of which currently Aerospace forms about 60%.
a backWard glance at past acHievements
continually striving for excellence
mission statementTo sustain world class supplier status within the
high technology engineering sector, employing
best industry practices and upholding the highest
professional standards to maintain market
leadership.
Ralph Jones
Chairman
our peopleApprenticeships & Training
Preci-Spark clearly understands that whilst investment in new technology is
important, investment in people is essential and prides itself in its commitment to
its employees.
Throughout its history Preci-Spark has benefited from 82 employees exceeding
25 years service to the company. Over the years we have had 130 apprentices
complete their apprenticeships. Many of whom are in managerial, supervisory or
skilled positions.
people synergy boosts efficiency and drives productivity
apprenticesHips are tHe key to developing tHe next generation of skills
To date we have trained over
450 people to NVQ level 2 and
level 3. It is compulsory for
all semi-skilled employees to
undertake the NVQ programme.
processesLaser Machining
Having recognised the potential for YAG laser machining over 30 years ago Preci-
Spark remains at the forefront of the technology. Having designed and developed
our own machine tools we have the knowledge, skills and experience to deliver
bespoke laser processing solutions to our customers.
Our laser machining service enables flexibility in development and robustness in
production, whilst always maintaining cost efficiency and price competitiveness.
Preci-Spark offers laser cutting and laser joining technologies. Our laser machining
scope extends from 3 axis through to 6 axis, up to 1.5m³ envelope, laser cutting
from 0.15mm to 7mm and laser welding from 0.25mm to 8mm penetration.
laser macHining offers HigH productivity enabling cost efficiency
Electro-Discharge Machining
Preci-Spark’s foundations were based on electro-
discharge machining. Since the acquisition of our
first Wickman EDM, Preci-Spark has strived to stay
at the forefront of the process technology through
innovation and investment. This process still delivers
cost-effective solutions in many applications, multi-
head and multi-channel generators enable high levels
of production throughput whilst maintaining part to
part repeatability.
Across our 6 manufacturing facilities we have 125
electro-discharge machines available for sub-contract
work. This extensive portfolio of machine tools
covers almost all applications. When required we
have the expertise to build special-purpose machine
tools and generators.
multi Head and multi cHannel generators boost productivity
processesConventional Machining
We have two state of the art conventional machine shops. The core of our
conventional machining capacity is based around simultaneous 5axis mill/turn
machining centres. In our experience this configuration of machine offers the
optimum level of flexibility, enabling almost all machining operations to be
performed within the given envelope.
Grinding capabilities combined with high pressure flushing allow the machining
of honeycomb structures to demanding specifications. Using our rotary surface
grinders we are able to machine components to tight tolerances up to Ø800mm.
5 axis mill/turn macHining centres offering optimum flexibility and productivity
Vacuum Brazing
Vacuum brazing and heat treatment cycles can be run automatically up to a maximum
temperature of 1350°C without oxidation of discoloration. We operate 6 vacuum
furnaces located within a process cell within out Falcon Street Facility. Our furnaces
are in the ‘clam shell’ configuration and have a capacity for components 1000mm in
diameter and 1000mm high for heat-treatment or brazing in either high vacuum or
partial pressure.
This process is key to the fabrication of many of our assemblies. A wide range of
alloys can be brazed using a variety of filler metals such as gold, silver or nickel. It is
an essential alternative to welding where thin sections, cracking or distortion can be
problematic.
Preci-Spark’s overall machining and brazing facility allows the removal and
replacement of damaged or worn honeycombs. Brazing of honeycomb segments onto
rings, heat shields or vanes is routinely carried out on new and repaired components.
Sophisticated machining capabilities enable the braze gap to be carefully controlled.
tHe vacuum brazing process enables tHe jointing of even tHe most intricate fabrications
processesInspection
Preci-Spark has full inspection and metrology capability to ensure quality of
product is assured.
Quality engineering input into product development is critical and through quality
planning and measurement systems analysis we ensure product compliance and
robust processing.
We produce first article inspection reports to AS9102.
On-going compliance is assured with conventional measurement techniques along
with co-ordinate measuring machines utilising the latest software systems. Co-
ordinate measuring machines are integrated into all of our machining cells.
Nadcap approved non-destructive testing capabilities of fluorescent penetrant
inspection along with final visual inspection by trained and competent staff
provide customer eyes over-check of all products prior to despatch which
contributes to maintaining class leading quality standards.
a complete portfolio of inspection tecHniques
Advanced metal forming
Preci-Spark has become renowned for its ability
to produce some of the world’s most challenging
components.
We have an extensive range of forming techniques
at our disposal which with the correct application
enable us to form even the most complicated
geometry.
As with all of our engineering activities our forming
techniques are process-based and deliver robust and
dependable performance. We operate two metal
forming process based product cells. Our capacity
allows for pressing up to 1000 tons with an envelope
of 1.2m².
multi process application alloWs complex material forming
processesWelding
With complex fabrications and assemblies being the mainstay of our
manufacturing operations TIG welding is a key process. We have vast experience
in welding thin sheet components to super alloy castings. Our pulse welding
technology enables the welding of advanced single crystal materials. For
applications where conventional argon backing will not suffice we utilise argon
chambers; this technique is essential when welding titanium or certain aerospace
alloys.
So whether it be welding cooling inserts into nozzle guide vanes or circumferential
welds on combustors, our experience and technology delivers high quality welds
time and time again.
HigHly skilled and experienced engineers fitting and Welding
productsCooling Inserts
Preci-Spark has been involved in the product
development and manufacture of air impingement
inserts for the cooling of gas turbines since 1960.
Our tried and tested proprietary method for
forming inserts has enabled us to deliver cost
effective solutions for inserts with even the most
complex geometry.
These forming methods ensure that profile
repeatability is maintained throughout the product
life cycle. Our manufacturing capacity allows for
high production volumes to be handled with ease.
1.8 million cooling inserts produced in tHe last 5 years
productsHoneycomb Assemblies
Preci-Spark manufactures honeycomb seals for high pressure turbines, low
pressure turbines and compressors. The company has secured significant market
share for the production and supply of both fabricated seal segments and seal
rings to the major OEMs.
Our manufacturing methodology delivers consistently high quality products and
enables us to supply over 20,000 honeycomb seals per annum across multiple part
numbers.
The synergy of sharing the customers design and our production expertise has
resulted in a culture of design for manufacture and delivered a step change in
product quality.
preci-spark manufactures and array of macHine Honeycomb seals
3 Dimensional Vanes
Preci-Spark has over 20 years of experience in
developing and manufacturing three dimensional
vanes. We produce an array of different types of
vanes with tapered and twisted shapes in alloys of
aluminium, steel and nickel.
Fabricated hollow airfoils are produced from sheet
metal with exacting contour definition. Airfoils from
forgings or bar stock can be produced with the use
of multi axis machining.
With demand for exacting quality and repeatability
of airfoil definition Preci-Spark has established
itself as a market leader in the production of these
components.
consistent product conformity
productsComplex Fabrications
With our extensive range of forming, welding, brazing and machining resources
Preci-Spark offers complex fabricated solutions to customers across multiple
industry sectors. Our capabilities allow us to manage even the most complicated
multi part assemblies.
Preci-Spark has been involved with combustion chamber development for the last
10 years, working in conjunction with leading engine manufacturers we produce
prototype combustion chamber components.
We were instrumental in the successful development of fabricated vane rings
which has enabled turbocharger manufacturers to obtain assemblies with specific
throat areas on vastly accelerated lead times.
Working in the semi-conductor industry we have developed some of our most
complicated fabrications. We have produced gas delivery systems with over
30,000 components and 80,000 braze joints.
specialist in complex fabrications and assemblies
General Components
Servicing the needs of a multi-industry customer base
we have developed expertise in the manufacture of a
diverse range of products from tungsten busbars to
titanium silencers.
We offer a comprehensive sub-contract facility and
with 125 EDM Machines and 25 YAG Lasers the
company is able to offer immediate capacity and
accelerated lead-times.
Whether it be impingement plates, heat shields or
gas purge manifolds our robust and dependable
processing delivers optimum productivity.
robust and dependable processing delivers optimum productivity
engineeringNew Product Introduction
New product introduction is a process for ensuring ‘Waste reduction and
Right First Time’ product realisation to agreed cost and timing, using available
Engineering and Quality tools.
Preci-Spark’s NPI process defines proven steps for product design and delivery.
Key milestone reviews are implemented to monitor progress. Our experience
in utilising the process assures quality through the early application of APQP,
budgetary control with an FMEA interface for risk mitigation and on time
delivery to customer expectation.
Product introduction is concluded with final sign-off to agreed specifications thus
ensuring that all necessary documentation and manufacturing aids are available to
begin production.
Allied to the NPI process, Preci-Spark operates a production validation process
that can utilise either First Article Inspection Reports (FAIR) or Production Part
Approval Process (PPAP) based on our customer requirements. Through these
processes we ensure that all of the customers’ engineering design and specification
requirements are correctly understood and that the manufacturing processes have
the capability and capacity to meet these requirements in production at a specific
rate.
resident experienced personnel
Solid Modelling
Preci-Spark offers its customers solid modelling
solutions. Our team of skilled engineers can
produce solid models from engineering functional
specifications. We utilise SIEMENS NX7 parametric
solid modelling system which significantly accelerates
the design process, lowers costs and improves
decision making.
With solid models becoming a standard across many
industries we use Team Centre Engineering for our
product data management. This system ensures
the project content and documents are revision
controlled and available via a central database for
concurrent engineering activities.
parametric solid modelling accelerates product realisation
engineeringValue Engineering
We provide a value analysis and value engineering service. Through detailed
analysis of products we enhance the value of key components with the objective
of increasing overall product value and decreasing cost.
With 50 years in multi process manufacturing our extensive knowledge base
enables our engineers to systematically improve value whether it be through
design for manufacture or simply applying the correct manufacturing technology
to deliver optimum performance.
Preci-Spark prides itself on creating and maintaining close relationships with its
customers. Many of our most effective solutions have been created through this
symbiosis.
fabrications are often key to enHancing cost saving
Tool Making
High quality tools, jigs and fixtures are essential to
almost all manufacturing activities. Our tool making
activities fall perfectly in line with our approach
to new product introduction and form an essential
part of the ‘concept to production’ solution we offer.
Through being able to control and adapt our tool
making operations we are in a very strong position
to be both flexible and dependable managing even
the most complex and extensive tool suites in
accelerated lead times.
With predictive tool life systems in place our tool
makers are continually maintaining the quality of
our tooling ensuring production continuity.
HigH quality tools, jigs and fixtures are essential
quality systemsQuality Standard
Preci-Spark is committed to maintaining a Quality Management System of
the highest possible standard expected by our customers and chosen industry
sectors. In support of this, the company holds certificates of accreditation to
the International Aerospace Quality Group (IAQG) initiative AS EN 9100
Revision C for our Aerospace and Gas Turbine operations and International
Quality Management System ISO9001:2008 for all of our plants. Our NADCAP
approved processes include vacuum brazing and heat treatment, electro-discharge
machining, laser machining, welding and non-destructive testing.
nadcap approved in-House laboratory facility
Production Control
The Preci-Spark Production Control process is all about ‘Risk assessment and
mitigation’ in our manufacturing environment utilising our industry experience and
tools at our disposal;
Quality tools
• Design Failure Modes and Effects Analysis for our tooling and gauging items
• Process Failure Modes and Effect Analysis
• Control Plans detailing critical and significant characteristics
• Statistical Process Controls (SPC) for on-going monitoring for compliance to
specifications and standards
People
Our operators and inspectors are highly trained fully skilled professionals to the
highest industry standards for their areas of expertise, from using basic measurement
devices, multi axis CMM, Metrology and Non-Destructive testing (NDT) to a fully
operational Fluorescent Penetration Inspection (FPI) facility within our premises.
Continuous improvement
We are constantly looking for ways to improve and optimise our operations to
maximise value added benefits to our customers. We consistently introduce Lean
principles to every aspect of our operations without exception. By applying Lean
principles in bespoke ways, we exceed customer expectations and achieve business
transformation with superior performance year on year.
risk assessment and mitigation
Preci-Spark Ltd
Chapel Street
Syston
Leicestershire
LE7 1HN
Tel: +44 (0) 116 260 7911
Preci-Spark Ltd
Morley Street
Loughborough
Leicestershire
LE11 1EW
Tel: +44 (0) 1509 236 655
manufacturing facilitiesPreci-Spark operates 6 manufacturing facilities
in the United Kingdom.
Total manufacturing floor space 138,000ft²
(12,850m²) Total office space 17,200ft²
(1600m²)
All sites are data linked ensuring a seamless
integrated operation.
Preci-Spark Ltd
Franks Road
Hill Top Industrial Estate
Coalville
Leicestershire
LE67 1TT
Tel: 00 44 (0) 1530 277 200
Preci-Spark Ltd
Falcon Street
Loughborough
Leicestershire
LE11 1EH
Tel: +44 (0) 1509 236 655
Preci-Spark Ltd
Railway Terrace
Loughborough
Leicestershire
LE11 1HW
Tel: +44 (0) 1509 236 655
Preci-Spark Ltd
Trenant Industrial Estate
Wadebridge
Cornwall
PL27 6HB
Tel: +44 (0) 1208 814 655
www.Preci-sPark.co.uk