John Hyde — managing director of John Hyde Engineering, Stoke-on-Trent — is a believer in British manufacturing, and his belief is growing with every month that passes, thanks to the increasing number of examples of multi-national companies bringing work back to the UK from low-cost economies.
The John Hyde Engineering story is an example of all that is best about British manufacturing. Founded in 1989, the company is an offshoot of John Hyde’s great-grandfather’s company — Robert Hyde & Son (Holdings) Ltd — and it is now a thriving business with customers in the machinery, plant, earth-moving and engine-building industries across the UK, Europe and America. “We’re production machinists, serving companies where stock isn’t carried,” says John Hyde. “Our products go straight to the production line, so dependability is our competitive advantage.”
Initially, the company only machined steel castings; later, it branched out into iron castings and forgings. We were using old, less accurate and inefficient machines which produced expensive, poor-quality products. It became apparent that if we didn’t make a bold move, we would not survive.
“We took what was an easy decision at the time and bought our first Mazak machine, an FH 8800 horizontal machining centre with an eight-pallet Mazatrol flexible manufacturing system — FMS — which was installed in September 2001. Now, we only have two non-Mazak machines in our factory — and one of those we built ourselves!
“After just four weeks, our first Mazak was running manned for 10hr a day and unmanned for 9hr. Moreover, it was earning 60% more per hr than the older horizontal machines that it replaced. Within 12 weeks of its arrival, we had ordered a second machine and a further 16 pallets for the FMS. Many manufacturers are forced by their accountants to cut down the specification of the machinery they buy to the minimum. In my opinion — and experience — this is a mistake, because it reduces the effectiveness of their investment by more than the cost saving. You need to buy the best you can afford.”
One door closes . . .
However within months of John Hyde Engineering’s first Mazak purchase, two customers switched to sourcing from low-cost countries — and the market for one product was wiped out by the bankruptcy of Enron. “We went from having a full order book to losing two thirds of it in just a couple of months. Yet when one door closes another opens, and we began manufacturing parts for several new customers.”
John Hyde Engineering has also invested heavily in Mazak’s Integrex machines, buying an Integrex e-1060V II in 2008. “We reckoned that the machine’s five-axis technology would enable us to really stand out in the large-castings market, which is our forte. It was a conscious decision to get machines with bigger capacities, bigger machining envelopes and more power. We also use our Integrex machines to produce shock absorbers for mining trucks. This now only requires one operation, whereas it used to take two or three. Using just one machine also ensures that we save time and don’t compromise on accuracy. Speed is important; after all, time is money.”
The company now has a total of 13 Mazak machines, including two Nexus 6000-II horizontal machining centres, bought in July last year to accommodate a project for machining large cylinder heads. The machines allow John Hyde Engineering to produce 200 of the complex cast-iron cylinder heads every week.
In 2010, Cummins gave the company a Cummins Supplier Award for 100% on-time delivery to its Daventry plant. “FMS has been the most important factor in allowing us to achieve this performance,” says John Hyde. “This is the kind of service we aim to provide to all of our customers.”
John Hyde Engineering has seven machines incorporated into Mazak FMSs. “With FMS, we only need to operate on a two-shift rota rather than three, as the ‘lights out’ capability means we can have 24hr of machine operation with just 16-20hr of manning. However, the main benefits of FMS are the zero set-up time and the ability to instantly change to a different job. FMS adds considerable cost but brings greater benefits, which result in the investment being repaid within five years.”
With regard to the future, John Hyde is confident that the relationship with Mazak will continue to grow, especially with the rising number of leading companies that recognise the benefits of sourcing their parts in Britain.