Otley engineering firm looks to quadruple turnover in five years through government’s £100k KTP grant

“…the company’s goal is to boost turnover from £1.2m to £4m within five years…”

“…manufacturing, inspection and design processes will bring about incremental changes eventually moving towards investing in new systems and equipment…”

UNIVERSITY of Huddersfield experts are helping an award-winning Yorkshire precision engineering company to introduce advanced technology and manufacturing systems that will enable it to break into new global markets and quadruple its turnover.

The company is Otley-based Craftsman Tools Ltd.  Established for 60 years, it specialises in innovative methods of tool-holding and work-holding and also offers supply chain management services.  Now, it aims to diversify from sub-contract machining and increase its focus on designing and manufacturing its own products.  It sees opportunities for strong growth within tool-holding.

The company’s goal is to boost turnover in this sector from £1.2m to £4m within five years. Increased productivity, flexibility and efficiencies need to be achieved and a key to this is to embed a systems engineering approach and automated manufacture.

Key issues raised by the new strategy are to be addressed by a Knowledge Transfer Partnership (KTP) – financially backed by the Government body Innovate UK – formed between Craftsman and the University of Huddersfield.

Central to the KTP is the appointment of an Associate, based at the company.  It is a challenging, multi-disciplinary project that demands top-quality design and mechanical engineering skills.  The post has been awarded to Daniel Emsley, who studied for a MEng in Automotive Engineering at the University.

Daniel’s work will focus on the company’s Tool-Holding products investigating current manufacturing, inspection and design processes to bring about incremental changes.  His work will firstly look at short-term improvements and eventually moving towards investing in new systems and equipment.

The project seeks to create new intelligent tool-holding by incorporating “internet of things” sensing technology with dynamic models, enabling the prediction of surface finish during machining, and the ability to bore a hole with a greater length-to-diameter ratio, combating challenges facing many industries, including aerospace.

Daniel, originally from Stocksbridge in South Yorkshire and who now lives in Otley, will oversee the implementation and testing as the changes take effect.

The KTP’s academic supervisor is Professor Andrew Longstaff and the lead academic is Dr Simon Fletcher, who explained that the project was scheduled to last for a longer-than-usual 30 months because it is multi-faceted, dealing not only with technical solutions to production engineering issues, but also marketing and tool-holding.

“That’s the systems engineering approach,” said Dr Fletcher. “Craftsman aim to be more product-focussed and to increase their efficiency at manufacturing core products.

“Daniel will be using computer engineering tools such as finite element analysis for design optimisation and he will develop lights-out production for more of the firm’s products.  In order to do that he needs to design for manufacture.  It is not just designing for functionality, but with a consideration of production efficiency.

“He will also be looking at the ability to perform inspection on the machine and alternative shop floor inspection methods to improve throughput, so he needs practical engineering skills and a metrology mind as well.”

Craftsman Tools have a well-established partnership with the University of Huddersfield.  There was an earlier KTP that established on-machine probing to enable lights-out production.  The firm and the University have also been awarded a grant by Innovate UK to develop intelligent tool-holding for metal-cutting machine tools.