Bicester-based Seychell Engineering & Fabrication was established in 1985; for its first 28 years, the company produced high-quality components for a range of market sectors.

However, since being acquired by Roger Williams in 2013, it has focused on being a leading supplier to the motor-sport, automotive, scientific and medical sectors; this has been achieved through targeted investment in people and technology.

Significant changes have already been implemented, including the re-branding of the business and the launch of a new Web site (www.seychellgroup.com), the modernisation of all business systems and hardware, and investment in new machinery.

The latest stage of the ‘change programme’ has focused on the engineering and inspection departments, along with the appointment of Nev Frisby as engineering production manager in February. The company recently placed an order for a DMG Mori Ecoline 50 universal machining centre with 3+2-axis capability; a turning centre is to follow in the near future. Furthermore, Seychell has established a technical partnership with the Sheffield-based tooling and work-holding company WNT (UK) Ltd (www.wnt.de/en-en).

Mr Frisby said: “Investing in machines such as the DMG Mori is a significant step for us. Our aim is to be the best among our peer group. That is why we took the decision to form a technical partnership with WNT (UK) and maximise the performance of our cutting tools.

“I used WNT products at my previous firm and appreciate the benefits that the company’s logistics system gives me; being able to place orders up to 6:30pm and know that the tools will be here the next morning means we have the confidence to promise deliveries to customers that we couldn’t do with other tooling suppliers.”

One of the ways in which Seychell is reducing manufacturing costs is to look at every on-going production job as a turn-key package, with fixturing and tooling bundled together in order to eliminate as much set-up time as possible.

Mr Frisby says that a machine can be set and running within 15min of the works order being received on the shopfloor; he also knows that the tooling in the bundle is the optimum for the job, thanks to the input from WNT (UK). Moreover, operators can replenish any consumables, such as inserts or end mills, from the WNT Tool Service vending system that Seychell has installed.

In addition to the cutting tools from WNT (UK), Seychell also reviewed its tool-holding and work-holding requirements. One thought was to use shrink-fit tool-holders for solid-carbide cutters, but this would have involved additional investment, with the requirement of a holder for every tool shank. Mr Frisby decided to use WNT’s Centro P high-precision collet system, which combines precision with good power transmission capabilities — a run-out accuracy of 3µm and clamping forces up to 560Nm.

Moreover, each Centro P chuck is balanced to G 2.5 at 25,000rev/min. With regard to work-holding solutions, Seychell chose WNT’s ZSG2 vice system, which provides a universal clamping solution, being both a centric vice and a single vice in one unit. Mr Frisby says: “Having the ability to use the vices on five-axis as well as three-axis machining centres is a major benefit. The unit’s modular design — along with the availability of a wide range of jaw configurations — is also a big help, as is the fact that
the leadscrew is totally enclosed.”

The real measure of success regarding any ‘change programme’ is the impact on the business and its customers. Even though the initial stages were focused on getting Seychell ‘ready for business’, the company has already gained several new customers, plus a significant machining contract from a major automotive/motor-sport company to produce components for a new supercar (it seems that this contract will develop into a long-term strategic partnership).

In conclusion, Mr Williams said: “In a very short space of time, we have changed a solid business that was being run in a fairly old-fashioned way into one that is using the latest technology and processes. The encouraging thing is that we are already seeing a positive impact on sales, despite being at an early stage of our re-invention of the business; we could not have achieved this without the full co-operation of the entire workforce — and suppliers such as WNT (UK).”