Aaron Clayton, 20, a fourth-year apprentice toolmaker at Thorne-based Mason Pinder Toolmakers — part of Polypipe Building Products, which manufactures plastic piping and ventilation systems — has saved the company more than £300,000 by modifying an old mould tool and thereby securing its continued longevity.

This saving came about when Aaron fixed a design flaw on a tool used for making drainage ‘storm cells’. “The plastic injection mould tool kept breaking and causing flash. I came up with the idea of changing the shut-off area to prevent two mating parts rubbing, which was causing the problem.

“Doing this modification saved an old tool from being scrapped and another needing to be bought, saving my employer £300,000 and obviating the need for further repairs to the tool. It has now been running successfully for over a year, with no further issues arising from the parts being produced. It was a three-month-long project, but it was very satisfying to see all the work come together.”

Aaron’s brother Jordan, 23, also works for Polypipe Building Products and saved the company £240,000 in 2020; he designed and produced parts for an automated robotic system, keeping the work in-house.

Aaron started his apprenticeship at the University of Sheffield AMRC Training Centre in September 2018, after he decided to stop pursuing his A-Level courses because he was not enjoying them.

He is now working towards his advanced apprenticeship, which he hopes to complete in September, and is a keen advocate of apprenticeships. “Doing an apprenticeship is a great way for people to earn as they learn — and getting vital work experience.

“I had always enjoyed engineering at school, and doing an apprenticeship has really helped me get into a good working routine — and given me the solid groundwork to progress both academically and with my toolmaking.”