As a leading sub-contractor to the aerospace, defence and nuclear industries, Poole-based Aerotech Precision Manufacturing (www.aero-tech.co.uk) recognises that developing and maintaining skills is the only way the company can secure its future.

Apprentice training is therefore a priority, as is machine investment; both are examples of Aerotech’s determination to stay ahead of the competition.

Aaron Houston, Aerotech’s business development manager, says: “We are proud to say that more than 80% of our business comes from existing customers, and we attribute much of this to the way we have structured the business to provide a comprehensive in-house CNC milling and turning service that can accommodate a range of requirements — from the very small to the very large.

“Also, by working with long-established partners in areas such as fabrication, sheet-metal work and finishing, we can undertake and manage large packages of work.

“The theory is to maximise the scope we can offer with a single point of contact for the customer, thereby minimising their transactions and associated management commitments. This is proving to be of interest to many companies, particularly those that are looking to rationalise or, in some cases, reduce the size of their supply chains.

"Our business has grown in such a way that we are strong commercially and financially, which not only provides peace of mind to our customers but also gives us the ability to invest when required.”

To ensure continuity of skills, Aerotech has instigated an apprentice-training programme; every year, it takes on three apprentices who undergo a mix of on- and off-the-job training.

One of the challenges the company faced was blending the skills learnt by apprentices at college and in the company’s training environment with the ‘real-life’ world on the shopfloor, so it bought a number of machines to address that challenge.

Already a user of the XYZ ProtoTrak system, Aerotech chose three new milling machines from Burlescombe-based XYZ Machine Tools (www.xyzmachinetools.com) — an SMX 2000 and two SMX SLV turret mills.

Aerotech director Roger Foley says: “The user-friendly nature of the ProtoTrak control system was a key factor in our decision to purchase more XYZ machines. It is important that our apprentices understand the feel of different types of metal cutting. Anyone can learn to program a CNC system, but the real skill is understanding that what you’re asking the CNC machine to do is achievable.

The ProtoTrak-equipped mills and lathes that we have help us to provide that experience; they also provide a bridge between the training environment and the shopfloor.”

XYZ’s SMX turret mill range covers many bases; the smallest machine in the range is the EMX, with its 2.25kW variable-speed spindle and a work envelope of 660 x 305 x 406mm. The larger SMX 2000 has the same spindle as the EMX, but features a larger work envelope and a 1,270 x 254mm table.

With its SMX SLV, XYZ has created one of the largest turret mills available; this has an X-axis travel of 1,000mm and a variable-speed 3.75kW spindle with a range of 70-3,600rev/min. The SMX SLV also features hardened box slideways, allowing it to undertake heavy-duty work.

The SMX ProtoTrak controls fitted to XYZ machines at Aerotech can provide two- or three-axis control; they also feature conversational cycles for a multitude of pocket-, profile- and thread-milling applications — plus the drilling and tapping of single holes and bolt hole patterns.

Meanwhile, the AGE profiling software removes the need for lengthy calculations by the operator. ProtoTrak comes with a ‘Guess’ key; if a dimension is missing, the user simply approximates its position and the control works out the rest.

The control can also undertake 3-D profiling via an on-board DNC capability that allows it to accommodate programs of almost unlimited size.

Even though Aerotech was already an experienced user of the ProtoTrak control, the company took full advantage of the free training provided by XYZ to anyone purchasing one of its machines (three apprentices visited XYZ’s Burlescombe headquarters to complete their off-site training on the machines and control system).

In conclusion, Mr Foley said: “I am confident that our own skills base can pass on the knowledge that our apprentices need to use the ProtoTrak control and the machine to a high level.

"That said, when we buy a new machine, we feel it is always better to get the latest information and the latest training from the supplier, as we then know we are fully up-to-date with any new features that may have been developed.”