Sandvik Coromant’s approach to workforce challenges

A 2024 study by Deloitte and The Manufacturing Institute predicts that almost two million manufacturing roles could remain unfilled over the next decade if the sector fails to address persistent skills shortages. While resolving this shortfall will take time, manufacturers must still meet rising demand for increasingly specialised, highly complex components. In this article, Nicklas Bylund, head of engineering projects at metal cutting solutions specialist Sandvik Coromant, explains how the company’s Engineering Projects initiative offers a structured, component‑centred approach to help bridge the skills gap without compromising performance.

Across aerospace, automotive and general engineering, components continue to grow in complexity. Whether dealing with heat‑resistant alloys in aircraft engines or steel and aluminium parts for automotive platforms, manufacturers are expected to achieve tighter tolerances, improved surface finishes and unwavering repeatability — all while facing mounting cost pressure. These expectations place ever‑greater demands on tooling strategies and machining processes.

Traditionally, many manufacturers have relied on trial-and-error methods to refine production, compensating for a lack of specialist machinists, programmers and engineers. Yet as component design and material science advance, these legacy approaches are increasingly inadequate. They introduce unnecessary inefficiencies, variability and risk, and they absorb time and resources that are already in short supply. As Deloitte noted in its 2025 Manufacturing Industry Outlook, industry now requires “new approaches and tools that can be leveraged across the business to maximise efficiency and build resilience, and prepare for a potential new era of industry expansion.”

Meeting this need requires a method capable of aligning tooling choices, machining strategies and process data into a cohesive system that supports consistent, high‑quality, repeatable production. Sandvik Coromant’s Engineering Projects have been developed precisely for this purpose.

Shortage of specialist expertise
Engineering Projects is designed to enhance the capability, stability and output of machining processes for critical components. Developed in response to the dual pressures of rising component complexity and a shortage of specialist expertise, Sandvik Coromant engineers provide structured, end‑to‑end support throughout the production chain. Working closely with customer teams, the engineers draw on deep experience in tooling, machining, CAM programming and parts processing to deliver a complete, production‑ready tooling package.

Each project begins with a detailed consultation. Sandvik Coromant engineers assess component design, material specifications, tolerances, machining requirements and production targets. By understanding these parameters early, the team can determine whether existing equipment can be optimised or whether a tailored strategy is required, while also anticipating likely challenges.

Tooling specialists then design or select the ideal mix of standard and special cutting tools, adaptors and work‑holding solutions, with CAM strategies and tool path optimisation factored in from the outset. In advanced applications — such as aerospace components manufactured from difficult‑to‑machine materials or high‑volume automotive parts — this often results in hybrid tooling packages combining proven standard solutions with specially engineered tools. Sandvik Coromant’s acquisitions also provide access to custom work‑holding solutions where required.

Once the tooling concept is complete, CAM programmers translate the strategy into full production‑ready programs. Using platforms such as Mastercam, Siemens NX and Vericut, programmers model toolpaths, feed rates and cutting sequences digitally. This virtual validation helps identify potential collisions, optimise cutting forces, predict cycle times and, crucially, eliminates the need for time‑consuming and expensive physical trial-and-error. Even operators without deep specialist expertise can run complex processes with confidence because the workflow has already been proven digitally.

Fine-tuning the process
After finalisation, tooling packages are delivered as precision‑balanced, spindle‑ready assemblies with complete technical documentation. Engineering Projects personnel, supported by Sandvik Coromant account managers and local experts, oversee initial set‑ups and test cuts, applying real‑time expertise to confirm dimensional accuracy and surface integrity and fine‑tune the process as needed. Once validated, workflows can be deployed across global production sites. Sandvik Coromant’s coordinated cross‑border project structure ensures consistent communication, aligned production standards and secure supply management across markets.

By leveraging specialist knowledge, digitally validated workflows and data‑driven insight, Engineering Projects provide measurable gains in efficiency, consistency and productivity. With these capabilities in place, internal teams are freed from repetitive troubleshooting and trial‑and‑error experimentation. Instead, they can focus on building long‑term organisational strength through knowledge sharing, cross‑functional initiatives and mentoring.

Over time, this structured approach establishes a platform for continuous improvement and sustained operational resilience. Stable, repeatable processes allow manufacturers to scale complex production confidently while maintaining high quality and adapting to future demands. Together, these improvements support what Sandvik Coromant describes as Manufacturing Wellness — a state in which production systems are robust, efficient and beneficial for both people and wider society.

As manufacturing complexity continues to accelerate and skilled talent remains scarce, long‑term success will depend on solutions that deliver consistency and confidence straight to the shop floor. Engineering Projects provides the tooling expertise and global support structure to achieve this, helping manufacturers navigate the skills gap while delivering predictable, high‑quality outcomes.