XYZ 800HD improves efficiency at Jim Lawrence

XYZ 800 HD fitted with Nikken tilt rotary table and Renishaw probes

There is an English figurative expression ‘when needs must’ and in 1994 this term was exactly what Jim Lawrence had to do as the realisation that rearing pigs and cows on a small-scale farm in East Anglia was not going to be profitable. Being of a resourceful nature, he set up a forge in one of his farm buildings and began to manufacture items for friends and neighbours before embarking on setting up what has bevolved into a ‘go to’ company for lighting and home furnishings.

From those humble beginnings in the barn creating candlesticks and chandeliers, Jim Lawrence Traditional Ironwork Ltd now resides in a facility in the market town of Hadleigh, Suffolk. This move away from the farm was mainly due to the company’s growth but, it was also driven by the fact the staff did not enjoy driving down a bumpy farm track to work every day. This relocation in 2000 to its current premises, allowed for the growth of the workshops, warehouse, offices and the creation of an impressive showroom to take place. Now with a headcount of over 150 people which include engineers, welders, painters, seamstresses, designers and lampshade makers, Mr Lawrence stipulates that the classic, high quality products the company produces, wherever possible, are made in the UK.

Capacity in the workshop is mainly taken up with production of parts used on a range of lighting products manufactured by the company. With the growth that the company have had to embark on, particularly during the Covid-19 pandemic when they virtually ran out of stock, Mr Lawrence‘s focus is firmly on making investments to ensure that productivity remains high and efficiency gains can be had to keep up with demand. That is one of the reasons that the company recently approached XYZ Machine Tools to look at more effective ways of manufacturing the housing of its popular Harbour outdoor lights.

Pictured right: Jim Lawrence Traditional Ironwork uses Renishaw probes to set datums on XYZ 800 HD

Production manager Chris Moore explained: “We were machining these housings in six operations with the added complication that they are coming from a brass casting. The aesthetics of these lights are important to our customers so ensuring that the two parts fit together correctly and the wiring inlets are central to the boss is of paramount importance.”

Having provided drawings and samples to XYZ Machine Tools, the applications team looked at how the cycle time could be reduced and that every single one of the housings machined looked aeshetically pleasing. XYZ suggested its 800 HD vertical machining centre fitted the bill with a Nikken 5AX-201, five-axis tilt rotary table and Renishaw OTS table-mounted tool setting probe along with an OMP 40 spindle-probe arrangement.

Mr Moore continued: “With the help of XYZ Machine Tools we have now reduced the machining of these parts to two operations. Having produced a fixture to hold the part on the bed for op1, the parts are then located on a fixture which sits in the tilt/rotary table where for op2, we can machine not only the main face of the housing but also the features that are located around the outside all in the same set up.”

User-friendly VMC
Although Jim Lawrence is not new to XYZ machine tools or the Siemens control fitted with Shopmill that drives the 800 HD, Richard Goodman, a CNC setter operator, joined the company just before the machine was installed but for him it is the first machine he has used with a Siemens control. Mr Goodman said: “The control is easy to use, user-friendly and it has been a great experience getting to grips with the package.” As a testament to the simplicity of the control, he has yet to receive any formal training from XYZ Machine Tools but the offer remains open to take that option up at any time.

Pictured left: the finished Habour Light Housing at Jim Lawrence Traditional Ironwork after machining on the XYZ 800 HD. Using the Renishaw probes has improved the aesthetics of the product

The compact XYZ 800 HD machine has given Jim Lawrence the opportunity to increase production without taking up a lot of floor space. With a footprint of only 2,440 x 3,190mm but still offering X, Y and X axis travels of 800 x 500 x 510mm, the machine accepted the Nikken table with its 200mm faceplate with ease. The machine’s spindle power of 21kW (28hp) also ensures that the materials machined for the light fittings can be removed efficiently using the 10,000rev/min maximum spindle speed and with a rapid traverse of 24m/min, moving between the two fixtures located on the table has also helped to decrease the cycle time. With a 24-station arm-type tool changer employing BT40 spindle tooling, exchanging tools between the new product and the existing machines aided flexibility within the workshop along with the ability to optimise the tool changing element of part production.

Mr Moore added: “Because of the nature of our business, it is a balance between holding enough stock to be able to react to the orders coming into the company but not holding lots of inventory. The result is that in the workshop we end up running small batches rather than volume production. This set up we have on the XYZ 800 HD with its Renishaw probing capability has allowed us to set the machine up quickly to react when stock runs low. This along with the probing of the part ensures accuracy when setting a datum, has proven to be a real game-changer for us.”

The efficiency gains and quality of the parts manufactured on the XYZ 800 HD are becoming even more relevant to the business. As Jim Lawrence Traditional Ironwork continues to be committed to ensuring manufacturing of its high-quality products is carried out in the UK, along with the desire to offer an excellent customer experience when purchasing one of its products either online or by visiting the showrooms in Hadleigh, Bath or the soon to be opened store in London, staying ahead of any competition is paramount and this investment is one small step that is helping the company achieve its goals.