More than a quarter of the 51 people employed at Mollart Engineering’s sub-contract manufacturing facility in Resolven are apprentices (www.mollart.com).

This focus on training is key to the company’s programme of developing its in-house production skills to meet future plans and maximising the potential of the latest developments in manufacturing technology that Mollart continues to invest in.

Director Wayne Thomas says: “To ensure our long-term success in the type of work we are undertaking, our company must have advanced processing capabilities and be very cost-effective. This means that as we continue to invest in the latest machine tools, equipment, systems and software, we must also invest in the people required to manage and operate them.”

Mollart Engineering has progressed to become a key supplier to sectors that include semiconductor, medical, defence, sub-sea, metrology, nuclear, and oil and gas; the company has also invested some £4 million in its operation over the last three years.

“It is now our objective to enhance our existing skills base with younger people, thereby creating a highly motivated and knowledgeable production team that spans all ages and is willing to transfer skills and expertise to allow the business to develop as a high-technology-based sub-contract operation.”

Formal training Mollart has 13 apprentices at Resolven and four at its Chessington headquarters; each apprentice undertakes three years of training. In addition, Chessington has three postgraduates working on special projects. At Resolven, 11 of the apprentices are training to be machinists, and one of them — a young lady — is also gaining experience in inspection and measurement.

In addition to training as a machinist, another of the apprentices is undertaking a welding apprenticeship in the company’s recently established welding and fabrication facility. An electro-mechanical apprentice is also being trained.

He will pursue an electronics career and work on the high-value assemblies and coolant systems designed and produced at Resolven; he will also work on the electrical panels destined for the deep-hole drilling machines built at Mollart’s Chessington headquarters.

Managing director Guy Mollart says: “The types of high-technology equipment we have installed can be quite challenging — and daunting — for a young person to set and operate, but I am totally supportive of pushing them forward. We have found that with careful training and guidance — and by working closely with them to build their skills — they quickly appreciate how rewarding manufacturing and engineering can be.”

Already well advanced, second- and third-year apprentices are creating some of their own programs, selecting and setting tools and even operating high-value and complex machinery such as a Mazak Integrex, a Mazak VTC800 and a Doosan DNM four-axis machining centre.

Mr Thomas says: “You should see the pride in their faces when they stand back and realise what they have achieved, especially when they get a ‘well done’ from one of the older operators.”

Playing a key role in Mollart’s development programme is apprentice-training and project engineer Liam Jeffreys. An ex-apprentice who progressed in the automotive industry to become a production line team leader and project leader (machine setting), he joined Mollart seven years ago.

He first worked at Chessington for a year to develop his gun-drilling and deep-hole machining experience before moving back to South Wales. Three years ago, he was asked to help train Mollart’s first two apprentices as machinists; he worked with Mr Thomas to create a programme that embraced all the main areas of production.

Dedicated training area

Today, part of the shopfloor at Resolven is a designated training zone, kitted out with machines that, in addition to being used for producing test pieces associated with training, also undertake regular production work while being operated by the apprentices. These machines include a newly installed Mazak Quick Turn Nexus 250-ll MY four-axis turning centre, a Takisawa three-axis lathe, a Mori Seiki four-axis turn-mill centre, and a Haas four-axis machining centre. There is also an inspection area with a Romer portable 3-D measuring arm.

Mollart has also established a strong relationship with nearby Neath Port Talbot College’s (NPTC) School of Engineering, which is one of the largest further education providers in Wales. NPTC is also involved in Mollart’s selection of apprentices from suitably qualified students (as a minimum, they must have GCSEs in maths, english, science and computer skills). Potential apprentices have to progress through two interviews, as well as pre-enrolment tests.

At NPTC, the apprentices start a foundation apprenticeship that lasts for two years and brings them up to semi-skilled status (Level 2). In their first year, they learn about health-and-safety issues and are taught basic machine operating skills; they also learn how to read and interpret a drawing, as well as carry out basic machine tool setting and operating.

In their second year, the apprentices learn about work-holding, fixture design and fixture build; they also begin programming and setting machines on the shopfloor at Resolven. Furthermore, they attend courses offered by certain of Mollart’s suppliers, such as those providing tooling and coolants; they also take part in team-building courses.

In the third year, Mollart brings everything together and really starts to develop the apprentices’ setting skills. They are involved with more-complex machines (including the Wenzel CMMs in the quality department), clean-room assembly and SolidWorks CAD/CAM software.

This year, the third-year apprentices attended programming courses at Mazak UK; at this stage, they are also working on a range of materials, including aluminium, titanium, Inconel and stainless steels. At NPTC, they are working towards the Advanced Diploma in Engineering Level 3, while their on-site assesments at Mollart see them progressing to completing the NVQ Level 3 Extended Diploma in Mechanical Manufacturing/Engineering.

In conclusion, Mr Thomas says: “What is interesting is the way our skilled setter/operators have responded to how these young people have taken to their tasks. In addition to providing all the help they can, some have asked to have more-advanced training themselves to broaden their skill base, which is a great motivator to help progress the business.”