Rugby-based subcontract specialist
Monard Precision Engineering has increased its turning capacity and accelerated its move towards lights-out manufacturing following investment in a new automated machining cell supplied by
Mills CNC.
The package comprises a DN Solutions Lynx 2100LSYB multi-tasking lathe, a Hydrafeed Multifeed 65 bar loader and a Hydrafeed Rotary-Pro parts accumulator. Installed in June 2026, the system was brought in to address growing demand from customers in sectors including industrial laser machinery, motorsport, pharmaceuticals, brewing and medical equipment.
According to managing director Kevin Hotchkiss, the investment was triggered by a major increase in requirements from an existing customer manufacturing industrial laser machine tools.
“Towards the end of 2025, an existing customer notified us of their intention to ramp up their production requirements for the forthcoming year,” he says.
Monard had previously supplied batches of 100 to 200 precision phosphor bronze adjustment screws, with turning and milling operations carried out on separate machines. When order quantities increased to 4,000 parts, the limitations of the company's existing production methods quickly became apparent.
“At that point we realised our existing machining methods and work scheduling resources would be pushed to their limits,” says Hotchkiss.
The situation was further compounded by rising demand from customers in Formula One, motorsport, pharmaceutical and brewing markets, creating production bottlenecks and stretching lead times.
Faced with mounting pressure, Monard carried out a comprehensive audit of its manufacturing operations to identify constraints and assess future capacity requirements.
“We needed to acquire additional machining capacity, and we needed to do it fast,” says Hotchkiss. “However, we wanted to make sure we were making a strategically sound and future-proofed investment.”
The review highlighted a number of legacy processes that required components to be transferred between machines for different operations. While effective for low-volume work, these methods involved additional set-ups, re-fixturing and labour input that became increasingly inefficient as batch sizes grew.
“It was fair to say that some of our existing processes were not as efficient as they could be owing to our reliance on older, less sophisticated machines,” he explains.
The audit confirmed the need for additional turning capacity while also reinforcing the benefits of a longer-term strategy focused on multi-tasking machine tools, one-hit machining and unattended production.
A Two-Stage Investment StrategyWorking with long-term machine tool supplier Mills CNC, Monard adopted a phased approach to increasing capacity.
The first step came in early 2026 with the purchase of a used DN Solutions Lynx 220L multi-tasking lathe and bar loader. The machine was dedicated to producing the high-volume phosphor bronze components and enabled the company to establish a transferable one-hit machining process.
“The acquisition of a used multi-tasking Lynx 220L lathe and bar loader got us out of a hole,” says Hotchkiss. “It gave us immediate additional turning capacity and the ability to develop and prove out a one-hit machining process.”
The second phase centred on the installation of the new Lynx 2100LSYB automated cell. Initially, the machine was deployed to reduce backlog work that had accumulated across a range of customer accounts.
A significant proportion of this work involved the machining of high-precision scientific instrument and annular probe system components for pharmaceutical and brewing applications. Produced from stainless steel tube and solid bar, these parts require tight tolerances and demanding surface finishes.
The latest investment also strengthens a partnership that stretches back almost a decade. Since Hotchkiss and business partner Martin Holloway acquired Monard Precision in 2017, the company has invested regularly in machine tools supplied by Mills CNC, including Lynx lathes and DNM machining centres.
“Our new and used Doosan and DN Solutions machines are reliable, flexible and deliver excellent cutting performance,” says Hotchkiss. “Whenever we are in the market for a new machine, we invariably make Mills CNC our first port of call.”
Driving Towards Lights-Out ProductionAt the heart of the new manufacturing cell is the Lynx 2100LSYB, a multi-tasking lathe featuring main and sub-spindles, Y-axis capability and driven tooling. The machine enables complex components to be completed in a single set-up, reducing handling time and improving throughput.
The integrated Hydrafeed Multifeed 65 automatically feeds bar stock to the machine, while the Rotary-Pro accumulator safely collects finished parts and protects delicate surfaces from damage.
Together, the technologies create a flexible automated cell capable of extended unattended operation.
With backlog work now largely eliminated and the major laser-industry programme close to completion, Monard is turning its attention to maximising the capabilities of the new installation.
“Machining parts to completion in a single set-up and achieving lights-out, unattended operations are where we want and need to be,” says Hotchkiss. “We now have the expertise and technologies in place to begin to make this a reality.”
For Monard Precision, the investment not only resolves an immediate capacity challenge but also lays the foundations for a more productive and scalable manufacturing operation as demand continues to grow.