A rapid response to customer requests has been a key factor in the success of Derby-based RJ Engineering. Formed in 1975, this precision engineering company has invested in new machine tools to meet the requirements of aerospace- and rail-industry customers, many of which have committed to long-term contracts for the supply of precision-machined components.

Managing director John McDonagh says: “We are proud of the fact that we have developed these long-term customer partnerships on the back of our investment and management strategies. Our commitment to deliver cost reductions for customers through ‘design for manufacturing’ processes and an ‘open book’ policy, has ensured that we have remained a key supplier to some of the leading names in the aerospace and rail sectors.”

One of RJ Engineering’s areas of expertise is the production of ‘specialist components’, many of them in low volumes or one-offs — and often on a rapid turn-round.

“To further improve this service, Mr McDonagh has introduced ‘Team Orange’. This is a dedicated machining cell that is focused on special projects and provides a rapid response, leaving the remainder of the factory free to handle day-to-day production runs.

This cell has been equipped with machines from Burlescombe-based XYZ Machine Tools (www.xyzmachinetools.com); they comprise SLX ProTurn lathes (two SLX 425s and an SLX 555), a Mini Mill 560 machining centre, two 2-OP vertical machining centres, and an SMX 5000 bed mill.

“Traditionally, we have had larger vertical machining centres; this resulted in them often being used on small components, which wasn’t always practical — and it tied up a larger capacity. By bringing in 2-OPs and the Mini Mill 560, we can ensure that we have the optimum capacity for most work.”

Although the 2-OP has been designed to be portable, RJ Engineering is using it as a front-line machining centre, with its eight-position tool-changer and 3hp BT30 spindle allowing it to be used for the complete machining of smaller components. This machine also features the ProtoTrak control system — as used on RJ Engineering’s SLX lathes.

Mr McDonagh says that the company has spent over £540,000 in the past four years. “We will continue to do what we do; that is to listen to our customers and provide them with the capability they require from us.

“To accommodate larger components in the Team Orange cell we bought an SMX 5000 with a 2m bed and an 850kg table capacity.

“The SLX 425 lathes give us the ability to quickly machine one-offs or small batches efficiently, while the SLX 555, with its 780mm swing, accommodates our mid-size work.

We are always looking to improve areas of our operation, and the XYZ machines and the ProtoTrak control have helped us to achieve that.”

RJ Engineering has invested time in training its operators to use ProtoTrak, which resulted in an immediate payback with the first 2-OP; within an hour of being commissioned, the machine was producing parts that had been programmed using the control system.

“Our Team Orange cell, with its XYZ machines, will provide us with the flexibility and versatility we need to meet the rapid response times that our customers require.

In a breakdown situation, they may have systems that cost many thousands of pounds an hour to run standing idle; our rapid response team is our way of making sure that they are up and running as quickly as possible.”

Vintage wheels

Another company that is benefitting from ProtoTrak-controlled machines from XYZ is Tractor Spare Parts Ltd, which supplies replacement components for Nuffield, Leyland and Marshall tractors from the 1950s through to the 1980s.

Run by the husband-and-wife team Andrew and Joanna Griffin, the company is based in the picturesque village of Alstonefield in the Peak District National Park; however, its products travel across the globe, with customers as far afield as New Zealand, Australia, Chile and Africa.

It was the combination of Mr Griffin’s tool-making background and a passion he shared with his father for restoring a Leyland 285 Synchro tractor that resulted in him starting the business.

When it proved impossibleto source a couple of parts, Mr Griffin used his skills to make them; he also made a spare set and sold them on.

That was back in 2001; and from those two parts, the business now offers an extensive range of components. These include new and re-manufactured parts — plus bespoke parts to customer specification.

Mrs Griffin says: “We can supply just about anything and everything, not only for tractors but any machinery that uses specific Leyland and BMC engines for a range of applications — from marine to excavators.

In many cases, if we can’t supply parts the customer would struggle to get them elsewhere. Andrew also uses his engineering skills to support the local farming community, producing one-off parts to keep machinery running.”

In order to meet the demand for a quick turn-round on low-volume parts (and with his original milling machine coming to the end of its life), Mr Griffin bought a two-axis SMX 2000 turret mill, along with the optional DXF converter.

“For many of the parts we make, I have to create new CAD files, as drawings either never existed or the originals are long gone. The ability to then export the DXF file straight to the ProtoTrak control is a big advantage.

“The support from XYZ is also a big plus. When the machine arrived, I struggled to get to grips with the DXF side of things, but XYZ sent an applications engineer out to us — here in the middle of the Peak District. He spent time explaining the system, and soon everything fell into place; now, it is second nature.

“Moreover, with batch quantities typically between 1- and 10-off, the SMX 2000, with its ProtoTrak control, is ideal for our needs — and it readily accommodates the occasional large batch of repeating parts that we produce.”

The SMX 2000 can be specified with either a two- or three-axis DRO for manual use; for more productivity, the two- or three-axis ProtoTrak control can be specified.

A 2.25kW R8 spindle (30 ISO is an option) with variable spindle speed between 75 and 4,200rev/min accommodates most applications undertaken by Tractor Spares, while the work envelope of 762 x 380 x 400mm is complemented by a ram travel of 450mm and a quill travel of 127mm.

In conclusion, Mrs Griffin says: “The tractor-spares side of the business is all mail-order via our Web site, but due to the nature of the parts we are producing — and the age of the vehicles they are being fitted to — there may have been modifications along the way.

“Therefore, we tend to contact customers directly and discuss what they actually want. These conversations allow Andrew to use the XYZ SMX mill to tailor the parts to exactly what is needed. We are then confident about shipping them half-way around the world, knowing that they will fit.”