Doubles under roof shop floor space with alterations and purchase of building next door.

In the past we have always reported how the management of a sheet metal processing company has realised that to grow the company they need to offer more services than just being a job shop service centre offering high-mix, low volume work. It could also be that clients are requesting that other processes must be done on the component so as to lessen their burden before fabrication or assembly. Decisions would be made and other metal processing equipment would be added to the shop floor. Most of the time a lathe or a machining center would be purchased to add value and extend the capabilities of the company.

Never have we reported it the other way around where an established CNC machining shop breaks its comfort zone and ventures into the sheet metal processing arena and purchases a laser cutter. That is until we visited fast growing Matthew and Son Engineering, a company that we have reported on previously. (https://metalworkingnews.info/matthew-and-son-reborn/ https://metalworkingnews.info/new-doosan-vertical-machining-center-cuts-production-time-at-matthew-and-son-engineering/ https://metalworkingnews.info/matthew-and-son-engineering-reach-40-year-milestone/ https://metalworkingnews.info/matthew-and-son-engineering-links-into-transport-industry)

Matthew and Son have purchased a JFY BFC 3015 fiber laser. The machine has a 6kW source and a bed size of 3m by 1.5m. The company mainly cut steel from 0.8mm up to 20mm but it is capable of cutting up to 25mm thickness. They are also processing stainless steel on it

“In previous reports we have always given the stock quote: ‘The resultant increase in component machining forced us to take a serious look at our capabilities, capacity, services and operational systems and equipment.’ Well this time we can give the same quote but also add that we have also looked at our metal processing services that we offer. And it is not just about spindle power anymore, although we have added a number of CNC lathes and are expecting some more deliveries in the coming months,” said Matt Mayhew (Matthew Mayhew Jnr.).

“We are now up to 24 CNC machines and only two of the older generation machines are left which will be replaced in the near future. All of our new purchases over the last eight years have been DN Solutions machines. This year alone we have installed 9 new DN Solutions machines and a further one is arriving next month. And another two machines will arrive a couple of months further down the line.”

“Choosing a single brand of CNC machine tools enables our operators to be self-sufficient. They can quickly learn to set up and programme virtually any machine in the shop. Another benefit of this strategy is that the shop can quickly get new machinists up to speed, not only running machines but, also setting them up and programming them.”

“Our growth continues to be in the rail transport industry. We have had clients in this sector for a number of years and they have been very good to us. However, we are also machining components for some large corporates that are involved in the mining, automotive, water and paper industries and we have some very decent contracts with these clients.”

Matthew and Son have also invested in a JFY TPM8 150 press brake that has a bending force of 150 tons and a width of 3 100mm

“As our capacity increases and is rapidly filled we have also had to look at alternative operations to make our machining more efficient. Artificial intelligence and autonomous robot technologies are advancing with manufacturers finding new applications that can enhance your operation. We have already started with the introduction of our first Fanuc cobot. We are in the early stages but we expect them (the cobots and robots) to be a big part of our future plans.”

Operator fatigue
Machine-tending robots are often key components used to enable unattended or lights-out machining operations, adding capacity by taking advantage of time that’s currently unused, like nights and weekends. In many cases, robot integration enables shop floor employees that were previously loading and unloading parts from machines to perform duties of greater value. Plus, today’s robots are faster and more intelligent than in years past and are also becoming increasingly viable for small-batch/high-mix production. In addition, collaborative robots, or ‘cobots’, use sensor technology that enables them to function safely alongside humans in a shared work environment. That means no more isolating fencing is needed to separate worker and robot. There is also the operator fatigue that you have to consider.

Introduction of JFY fiber laser and press brake
“When we do part-assembly for clients, especially in the rail transport industry, there is a sizeable amount of sheet metal components that are required. We have always sub-contracted this work out but there comes a time when the numbers start to tell you that maybe you need to look at an alternative.”

“This has happened to us and we have addressed the situation. Everything was pointing towards us procuring our own fiber laser cutting machine. We had reached that number where it justified us purchasing our own machine. There are many other reasons that swayed us to go this route. I am sure we are not the first. I have read that many fabricating and assembly type companies that manufacture their own products have gone the same route. They may not fill the capacity of the laser or press brake but at least they are comfortable with the in-house control.”

Matthew and Son are looking at using machine-tending robots for the repetitive work

“It is unusual for a business that has machining components as their primary operation to then introduce laser cutting and press brake bending. But if it is justified, why not.”

“We have purchased JFY BFC 3015 fiber laser. The machine has a 6kW source and a bed size of 3m by 1.5m. We mainly cut steel from 0.8mm up to 20mm but it is capable of cutting up to 25mm thickness. We are also processing stainless steel on it.”

“It is a relatively small machine but we do not need bigger for what components we are processing. Besides the bigger machines take up some valuable real estate. At least now we are in control of quality, delivery and many other aspects. On the numbers side we were looking at 12 to 15 months return but we have already halved that.”

“We have also invested in a JFY TPM8 150 press brake that has a bending force of 150 tons and a width of 3 100mm. The capacity for this machine is very under-utilised but we are not concerned as we are adding value to components for our clients. You can also make the analogy of having CNC lathes but no CNC milling machine. Inevitably you need work to be done on the milling machine that the lathe cannot do. The same is for flat sheet processing. You won’t just cut you will also need to bend. They go hand in hand together.”

“Both machines were supplied by Puma Machine Tools, the same supplier of our CNC machines.”

“We are still learning the art of cutting and bending but if I look at what we are producing so far it is way, way better than what we were getting from outside sources. We look at the new processes from a machinist’s perspective where we work in microns of 10 whereas a laser service centre is not that concerned when it comes to accuracy. I am generalising but our operators take care when setting up the machine to get the best results, as they have to do with the CNC machines. It is also a big advantage that we are not operating on tonnage out the door – all cut and bent components are for our own use. It makes a difference.”

Matthew and Son have this year installed 9 new DN Solutions machines and a further one is arriving next month

“However, the biggest challenge over the last two years has been about space to house the new equipment that we have purchased and to enhance the quality and metrology disciplines that are a requirement for us.”

“We first finished the additions and alterations to the current building and that now houses the laser and material storage. We had also been negotiating to purchase the building next door and this we secured in 2023, increasing our footprint to 5 000m². Then the real task of turning the facility into our high standard began and that took time and was a project management challenge as we were having machines and material delivered while construction was still taking place.”

“Now that it is almost finished, we are very happy with the outcome. Besides housing all the new DN Solutions Puma 2100MB horizontal single turret lathes it also houses our Kasto bandsaw which processes a fair amount of our material. We have just imported 400 tons of material from China and we are comfortable with having material stock that could cover between 3 and 9 months.”

“The whole of the inside of the two buildings, which are connected, have now been refurbished. We have also put in solar and currently we are implementing a biometric monitoring system for traceability and quality purposes. Additionally, our new measuring laboratory is busy being equipped. This will be temperature controlled so our quality control will be of the highest standards.”

“It has been a challenging two years but also rewarding when you see what we have achieved.”

For further details contact Matthew and Son on TEL: 011 609 5603 or visit www.matthewandson.net