Woodhey Engineering Company Ltd, in Bacup, Lancashire has been on the same site for 30 years. The company specialises in subcontract machining for the nuclear fuels, aerospace, textile and food industries. Components produced by Woodhey are at the larger end of the scale, frequently cutting parts 1.5 to 5m long and more in aluminium, steel, stainless steels and cast iron. For parts of this size, batch sizes are small, with quantities between 1 and 6 off being the most common.

<< WorkNC is very user friendly and reliable. It does all the thinking for you! >>
Russ Bailey, Joint Works Manager, Woodhey Engineering Company Ltd.

The company’s customers, in the high technology sector, send electronic CAD data, so the need to interpret and modify imported geometry for machining lead Woodhey to install WorkNC and WorkNC-CAD, so that it could step up to 3D. Adrian Briggs, Joint Works Manager for Woodhey Engineering commented, “WorkNC-CAD has provided trouble free translation of IGES data, allowing us to modify it to suit our customers and our manufacturing requirements.” WorkNC has also made it possible for Woodhey to quote for and win the type of business, which provides it with the maximum return. Russ Bailey, his fellow Joint Works Manager added, “We can cut 3D surface work more efficiently and reliably. We can also quote accurate delivery times and costs for each job.”

This new capability has enabled the company to build on an existing relationship with one of its major customers, winning Woodhey a contract to produce the largest tool in its history, cut from a solid block of steel weighing 10.5 tonnes. The crane capacity, the large size of machine tools and the ability to handle and machine complex 3D surfaces from imported CAD data were key factors in awarding the contract.

Because of the nature of this tool, a huge amount of roughing was required. Adrian Briggs explained, “We started by machining one side to within 15mm of the surface. This then goes for stress relieving. We then machine the other side, finally reducing the 10.5 tonne block to a surface 30mm thick.” For roughing with WorkNC the company used contour roughing, taking 1mm depths of cut and running at 40m/ min. using a 5 insert 66mm diameter Fette face mill from a local tool supplier, Riley Shutt. Finishing and semi-finishing used Z level and planar cycles to take out the rest material with 35 diameter button mill with 6mm tip radii. Adrian Briggs added, “WorkNC told us the tool lengths required for a 270mm deep gully, and enabled us to use two different lengths of tool and holder to get down to the required depth, while maintaining rigidity and making the best use of the 50Kw spindle power necessary to cut this type of job.”

Programming was completed very smoothly for a job this complex. Russ Bailey said, “WorkNC is very user friendly and reliable, we never get a gouge. It is flexible with many different strategies, and the stock model and rest model eliminate fresh air cutting. It does all the thinking for you!”

Because Woodhey was delighted with the service and support it got from Sescoi, it decided to invest in 5 WorkPLAN stations to control time and attendance, quotations, purchasing and to get a much better picture of the workshop. Adrian Briggs explained the process, “When the quote becomes live, the job card comes out automatically, controlling production right through to the invoice, tying all the paperwork together.” This is a particular benefit for the short lead times involved, providing improved traceability, accurate costing and work management. The operators also like the system as it enables them to check the status of their own work. Adrian Briggs was pleased with the implementation carried out by Sescoi, “The planned installation was phased to meet our needs. We were very happy with the training, configuration and ease of use of WorkPLAN.”

By working in partnership with Woodhey, Sescoi have fostered a close and valuable working relationship. Adrian Briggs said, “We envisage manufacturing more heavy tools in different materials. It would provide a significant boost to our business which we could not have achieved without WorkNC.”